METHOD AND SYSTEM FOR USING AND COOLING A PORTABLE HIGH-POWERED LASER

A system includes one or more diodes, a power source, a tank, and a cooling plate. The power source is coupled to the one or more diodes and the tank is operable to store a fluid under pressure. The cooling plate includes one or more channels configured to receive at least some of the fluid stored in the tank and is operable to transfer heat from the one or more diodes to the fluid through the one or more channels.

TECHNICAL FIELD

This disclosure relates in general to portable lasers and cooling systems, and more particularly to a method and system for using and cooling a portable high-powered laser.

BACKGROUND

High-power infrared lasers are known in the art for applications including welding, cutting, and fabrication for manufacturing, as well as military applications including strategic weapons, sensor disabling/dazzling (including human), and the disposal of unexploded ordinance. However, while today's lasers are much more efficient and reliable than their predecessors, no self-contained, human-portable lasers exist for these high-power applications. Typically, if a portable high-power application is desired, the power, optics, and cooling systems needed to support these lasers require mounting on a mobile platform or turret, typically on a land, air, or water vehicle. These systems weigh hundreds or thousands of pounds and require significant energy input in support. The human-portable laser systems available today lack the power to act as either incendiary weapon or welding system, and are typically only used for sensor denial, dazzling of human targets, or as laser pointers.

SUMMARY OF THE DISCLOSURE

According to one embodiment, a system for emitting a high-powered laser is provided. The system includes one or more diodes, a power source, a tank, and a cooling plate. The power source is coupled to the one or more diodes and the tank is operable to store a fluid under pressure. The cooling plate includes one or more channels configured to receive at least some of the fluid stored in the tank and is operable to transfer heat from the one or more diodes to the fluid through the channels.

According to another embodiment, a method for emitting a high-powered laser is provided. The method includes generating a laser using at least one diode mounted to a cooling plate and releasing a pressurized fluid stored in a tank. The method further comprises directing fluid through a channel of the cooling plate, wherein directing the fluid through the channel causes heat transfer between the at least one diode and the fluid.

According to yet another embodiment, an apparatus for emitting a high-powered laser is provided. The apparatus includes one or more diodes, a power source, a tank, a cooling plate, and a housing. The power source is coupled to the one or more diodes and the tank is operable to store a fluid under pressure. The cooling plate includes a plurality of channels, wherein each channel corresponds to at least one diode and is configured to receive at least some of the fluid stored in the tank and the cooling plate is operable to transfer heat from the one or more diodes to the fluid through the channels. The housing is configured to encase the one or more diodes, the power source, the tank, and the cooling plate.

Technical advantages of certain embodiments may include the portability of a stand-alone, high-power laser system. The system may be aimed and operated while moving or stationary, and the system can function for an operationally significant time without any external connections, such as to power or cooling systems. In some embodiments, the portable high-power laser system may be transported on a wheeled cart, mounted to a vehicle or a static platform, adapted for use in outer space, or used underwater. Further, certain embodiments described herein may use a novel cooling apparatus which stores high-pressure gases used to cool a device. This disclosure also recognizes technical benefits of combining one or more of the high-power laser systems described herein into a single output device or system thereby multiplying the available power output. The cooling apparatus may provide certain technical advantages, such as the absence of significant external noise or heat signature. Other technical advantages will be readily apparent to one skilled in the art from the following figures, descriptions, and claims. Moreover, although specific advantages have been enumerated above, various embodiments may include all, some, or none of the enumerated advantages.

DETAILED DESCRIPTION OF THE DISCLOSURE

To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. The following examples are not to be read to limit or define the scope of the disclosure. Embodiments of the present disclosure and its advantages are best understood by referring toFIGS.1through4B, where like numbers are used to indicate like and corresponding parts.

Conventional laser systems require heavy power and cooling systems and are unable to focus the output of power with a high level of precision at long distances. These conventional laser systems present a significant burden by way of transportation and operation. For example, a 400 lb gas generator and 400 lb water cooler are required to properly power and cool some existing laser systems. The laser of such systems, therefore, is unable to be self-contained and requires the support of additional, heavy and expensive components. All told, existing systems can weigh as much as 1500 lbs. And such systems are not rechargeable and thus have limited use in remote locations. In addition to the extra weight and expense, conventional laser systems also lack the ability to focus high power at long distances, reducing their utility for certain applications.

The teachings of the present disclosure recognize that these above problems can be addressed by providing a self-contained, portable, high-powered laser. Rather than rely on a separate and unduly heavy power supply, the present system may be powered by rechargeable lithium-ion batteries. The system may further contain a novel cooling apparatus that provides no significant external noise nor heat signature. Cooling may be provided by thermochemistry, rather than battery power, and cooling means may be stored as a compressed gas such as carbon dioxide (CO2). Both the power and cooling systems may be readily reusable and rechargeable. The system described herein may be capable of cutting or melting metal at distances greater than 100 meters, while outputting a laser beam that is both invisible and silent. Potential applications include tactical military weapons, welding, construction, and manufacturing. The following describes systems and methods for using and cooling a portable high-powered laser for providing these and other desired features.

FIG.1illustrates a perspective view of a high-power laser system100, according to certain embodiments. High power laser system100includes at least one diode102, a power source104, and a cooling apparatus, but may optionally include one or more other components as well. In some embodiments, system100may be self-contained. As used herein, this disclosure uses the term “self-contained” to mean that all components of system100are contained within a single unit or apparatus, and does not require external components such auxiliary power or cooling equipment. As will be described below in reference toFIG.3, system100may be contained within a housing.

As depicted inFIG.1, system100is configured to generate a laser using the at least one diode102, which is powered by power source104and cooled using a cooling apparatus. In some embodiments, such as that shown inFIG.1, system100is portable and self-contained, (i.e., power source and cooling apparatus are located internal to system100). The portability and self-contained aspects of this invention have several advantages, including the ability by a user to carry system100in a backpack and carefully aim the laser at target objects. In some embodiments, a laser may be outputted externally through fiber cable106.

Diode(s)102is operable to convert electrical energy into light to create the laser of system100. System100may include one, two, three, or any other suitable number of diodes102. Because laser diodes create significant heat, this heat must be removed to protect the diodes from failure or from causing thermal failures of other parts of the system. As will be described in further detail below, this disclosure recognizes providing a source of cooling for diodes102by performing a heat exchange facilitated by the controlled release of compressed fluid from a tank (e.g., tank108). Diode(s)102may be any type of diode suitable for use as a fiber laser, including a light-emitting diode. In some embodiments, diode(s)102may heat up and produce a laser beam that is amplified inside system100and is then directed outside system100via a flexible fiber cable106extending from a fiber cable portal110. In some embodiments, flexible fiber cable106includes an inner glass fiber which carries the laser beam. In particular embodiments, flexible fiber cable106is a single glass fiber less than 100 microns in diameter.

Power source104is configured to provide power to diode(s)102. Power source104may be any technology capable of operating as a source of power. In certain embodiments, power source104includes one or more batteries. In a particular embodiment, power source104includes one or more rechargeable lithium batteries. As will be recognized by one of ordinary skill in the art, power source104may be located in any suitable position. Accordingly, power source104may be located on, in, or through system100and be accessible, for example, from the exterior of system100via a battery cover. In certain embodiments, any number of batteries may be mounted to the interior or exterior of housing402, which may encase system100. Such batteries may have an integral attachment and protection structure, or alternatively may resemble portable computer batteries, remote control vehicle batteries, marine batteries, aviation batteries, or automotive batteries. In other embodiments, power may be provided directly or indirectly via other means of generation, including solar, wind, chemical reactions, or by combustion engine. In some embodiments, self-generated power or externally generated power is first stored in power source104or similar vessels for later use in system100. In a particular embodiment, power source104may also provide power to control processing hardware114or other components.

As described above, system100includes a cooling apparatus. As will be explained in further detail below with respect toFIG.2, the cooling apparatus of system100may include a tank108, one or more valves112, a manifold116, diffusion device118, and a cooling plate120. Generally, the cooling apparatus of system100provides the cooling necessary to prevent failures to system100.

FIG.1also shows that system100may include additional componentry, such as control processing hardware114and a diffusion device118. In some embodiments, the operation of diode(s)102and other structures (e.g., valves112) are controlled by control processing hardware114. Control processing hardware114is configured to provide requisite power and control signals to diode(s)102such that diode(s)102produce and amplify a laser beam, as discussed above. Control processing hardware114may provide requisite power and control signals to components of system100manually or automatically. For example, control processing hardware114may provide requisite power and control signals to components of system100in response to receiving an input by an operator. Alternatively, control processing hardware114may be configured to perform in an automated mode such that it provides requisite power and control signals to components of system according to an executable algorithm.

Control processing hardware114may also control the operation of valves112aand112b. In certain embodiments, control processing hardware114may open valves112aand112bin response to activating (or otherwise sending a control signal to) diode(s)102. In other embodiments, control processing hardware114may open valves112aand112bin response to a temperature determination. In such an embodiment, system100may also include one or more sensors communicatively coupled to control processing hardware114and configured to detect temperature. Such sensors may relay temperature information to control processing hardware114for use by control processing hardware114. As an example, in response to receiving temperature information from a sensor, control processing hardware114may compare the received temperature information to a temperature threshold stored in control processing hardware114and, based on the comparison, determine to send a control signal to one or more of valves112to open. This disclosure recognizes that the temperature threshold may, in some embodiments, be the ambient temperature. As such, this disclosure also recognizes that control processing hardware114may further be configured to determine temperature differences between external and internal surfaces of system100such as, e.g., by positioning one or more sensors on both the external and internal surfaces of system100. In some embodiments, the temperature information sensed by the one or more sensors may include temperature information related to one or more diode(s)102. Opening valves112aand112bmarks the start of the process that results in the cooling of diode(s)102. In a particular embodiment, all electronic control may be provided from within system100. In alternative embodiments, electronic control may be provided remotely, for example via a handheld device such as a phone, tablet, or custom interface device, by cloud or network at a distant location, or by any combination thereof.FIG.2illustrates a perspective view of a cooling apparatus200, such as the one described above with regards toFIG.1. As shown inFIG.2, cooling apparatus200may include one or more of tank108, primary valve112a, secondary valve112b, manifold116, and diffusion device118. As discussed above, cooling apparatus200may provide cooling to system100to prevent failures, such as those caused by thermal heating due to inclusion of diode(s)102.

Tank108is operable to store a fluid under pressure. The term fluid is understood herein to encompass a gas, a liquid, or a combination of gas and liquid. In a particular embodiment, the fluid is carbon dioxide (CO2) gas, which has several beneficial properties for certain applications. For example, CO2is non-toxic, compressible, renewable, and becomes extremely cold when released from a pressurized tank. At high pressure, CO2can be stored as a liquid, or with elevated temperatures, as a material above its triple phase point. Any other gas or liquid may be used, however, those with properties similar to that of CO2may be preferred. This disclosure specifically recognizes that one or more of the following fluids may be used in the cooling apparatus described herein: Dichloro difluro-methane Freon-12 (R-12); Tetra fluro-ethane or R-134a or HFC-134a; R-22; R-410A; and R-32. This listing, however, is exemplary. Furthermore, this disclosure recognizes that system100, generally, including apparatus200, may be either open (i.e., fluid is released after decompression/heating) or closed (i.e., fluid is captured and recompressed for re-use after decompression/heating), and that the open or closed nature of such system may depend on the application (e.g., closed system may be particularly beneficial for space applications).

As stated above, tank108is operable to store a pressurized fluid. Tank108may be rated to store any desired psi (e.g., 4500 psi), but is preferably at least 700 psi. Tank108may be composed of any material suitable for storing a fluid under pressure, including aluminum, titanium, or other light-weight metal. In some embodiments, tank108is composed of a metal alloy, such as steel. This disclosure specifically recognizes that certain materials may work better than others for storing a fluid under pressure. In a particular embodiment, tank108has an aluminum liner for corrosion resistance, and is jacketed in one or more of glass fiber, carbon fiber and resin.

Although this disclosure specifically describes and illustrates an embodiment using pressurized fluid to perform the cooling function described herein, this disclosure recognizes that cooling may be accomplished via other means such as, for example, using plain compressed air, blown air, or by flowing a liquid (e.g., air, water) through the channels. In such embodiment, system may include a modified cooling apparatus200that does not include, for example, tank108and/or ancillary componentry facilitating the flow of fluid into diffusion device118(e.g., valves112, valve orifice202, manifold116). As noted above, such embodiment might, for example, include one or more fans configured to circulate and/or redistribute air in a manner that provides cooling to the liquid flowing through channels of diffusion device118and/or cooling plate120, or the cooling plate120may simply have enough mass to act as a heat sink.

As discussed in reference toFIG.1, system100may include one or more valves100. As shown in bothFIGS.1and2, system100and cooling apparatus200each include two valves—primary valve112aand secondary valve112b. Although this disclosure describes and depicts system100and cooling apparatus200each including two valves112, this disclosure recognizes that any suitable number of valves112may be employed to achieve a desired outcome. Valves112aand112bare positioned between tank108and manifold116and are configured to control the flow of the fluid stored in tank108.

Valves112aand112bare configured to control the release of fluid stored in tank108. Valves112may be any suitable type of valve configured to control a flow of fluid. In a particular embodiment, primary valve112ais a one-way valve positioned at or near the mouth of tank108and controls the release of fluid (e.g., CO2) from tank108. In another embodiment, the mouth of tank108may be coupled to a hose or other structure having a channel for directing the fluid, and primary valve112amay be positioned at or near the end of the hose or channel, or at an intermediate point along such hose or channel.

In some embodiments, the release of fluid from tank108is further gated by a secondary valve112b. Secondary valve112bmay, for example, be a powered solenoid valve. Secondary valve112bmay, in certain embodiments, such as the one shown inFIG.2, include valve orifice202, which collectively act as a nozzle configured to induce the flow of fluid stored in tank108. As discussed above, valves112may be controlled in various ways, including but not limited to, manually, remotely by an operator or by a local or remote computer processor, or automatically by the control processing hardware114.

Opening of valve(s)112allows the pressurized fluid previously stored in tank108to flow into manifold116, where it is allowed to expand. This expansion of the pressurized fluid results in a reduction of both pressure and temperature. Where CO2is employed as the fluid in cooling apparatus200, the expansion may allow for the creation of atomized dry ice, or “CO2Snow.” In some embodiments, after expanding through manifold116, the fluid is directed to a diffusion device118, which distributes the cooled fluid into one or more channels (see, e.g., channel(s)204shown inFIG.2) therein. In certain embodiments, channels (e.g., channel204shown inFIG.2) direct the flow of the cooled fluid to one or more other channels in cooling plate(s)120located near diode(s)102. This disclosure specifically recognizes that channels (e.g., channel204shown inFIG.2) of diffusion device118may direct cooled fluid to one or more channels of a cooling plate (e.g., cooling plate120).

In certain embodiments, diffusion device118divides or otherwise distributes the flow of the cooled fluid into one or more channels (not illustrated) of cooling plate120. In some of those embodiments, each channel is associated with a single cooling plate120(not shown inFIG.2) and a single diode102(not shown inFIG.2). In other embodiments, a channel may be associated with a plurality of cooling plates120and/or diodes122. Diffusion device118may be shaped so that the cooled fluid is distributed in a substantially equal fashion among the plurality of channels (e.g., channel204shown inFIG.2). In an alternative embodiment, diffusion device118is shaped so that the cooled fluid is distributed in an unequal fashion among the plurality of channels (e.g., channel204shown inFIG.2). This disclosure contemplates that diffusion device118may be integral with, or separate from, manifold116.

Cooling apparatus200may also include one or more cooling plates120. Although not depicted inFIG.2, an example of a cooling plate120is shown inFIG.1. Generally, cooling plate120is configured to secure diode(s)102and to facilitate heat transfer between diode(s)102and the fluid flowing through cooling apparatus200. In a particular embodiment, each diode102of system100is mounted to a different cooling plate120of system100. In an alternative embodiment, more than one diode102of system100is mounted to a single cooling plate120. Diode(s)102may be mounted directly or indirectly to the cooling plate120. Additionally, this disclosure contemplates that cooling plate120may be integral with, or separate from, one or more of manifold116and diffusion device118.

Each cooling plate120of cooling apparatus200may be configured to receive fluid under a high pressure and reduce the fluid to a low pressure as the fluid flows through one or more channel(s) therein. The high pressure may be 1000 psi (69 BAR), suitable for maintaining CO2in liquid state at room temperature. The low pressure may be, for example, 14.5 psi (1 BAR). A majority of the reduction in the pressure of the fluid from the high pressure to the low pressure may occur in a portion of channel(s) (e.g., channel204shown inFIG.2) near diode(s)102.

FIG.3illustrates a perspective view of an exterior of system100, according to certain embodiments. As shown inFIG.3, system100may further include a housing402that encases the componentry discussed above with respect toFIGS.1and2. Housing402may comprise any suitable size or shape. In some embodiments, housing402includes one or more side walls302aand one or more ends302b. As illustrated inFIG.1, housing402has a hexagonal cross-section, having six side walls302a. Housing402in other embodiments may have more or less side walls302a(e.g., four sides or seven sides), and still other embodiments may have no distinguishable sides at all (e.g., rounded housing). Housing402may also include one or more rounded or straight side walls302a, or be a combination of both. As illustrated inFIG.3, ends302band side wall302acomprising housing402are coupled with tie rods and nuts. Although this disclosure describes and depicts a certain manner of coupling ends302band side walls302a, this disclosure recognizes that ends302band side walls302aof housing402may be coupled in any suitable manner. Furthermore, this disclosure recognizes that housing402may be constructed and strengthened with an assortment of different materials, such as carbon fiber, fiberglass, or metal, in addition to any other suitable material, alone or in combination.

As shown inFIG.3, tank108may be configured to fit within a cavity defined by one or more structures of system100. As an example, tank108may fit or otherwise be installed between a retaining structure integral to housing402. As another example, tank108may sit within a cradle positioned along the exterior of a side wall302a. In some embodiments, tank108is removable from system100. Tank108may be of any suitable size and shape, and in some embodiments may have a size and shape that, when installed within system100, extends beyond, or protrudes out from, end302bof housing402. As one of ordinary skill in the art will recognize, tank108may be configured to have a size and shape that enables removal from system100. As shown inFIG.1, tank108is accessible to a user from the exterior of housing402. Although this disclosure describes and depicts tank108as being removably installed within a housing402of system100, this disclosure also contemplates other embodiments wherein tank108is not removable from housing402and/or is not installed within housing402at all. For example, tank108may be located entirely within housing402such that it cannot be easily accessed or removed. As another example, tank108may be located remote from other components of system100and coupled to such components of system100by a hose or external plumbing.

As described above with respect to tank108, power source104may also be stored inside of housing402and may be accessible for removing and/or changing from the exterior of housing402. Accordingly, power source104may, in some embodiments, be secured in place by a retaining structure integral to housing402. In other embodiments, however, power source104may be coupled to the exterior of a side wall302aor end302b. For example, power source104may be configured to sit within a cradle positioned along the exterior of a side wall302a. In some embodiments, power source104is removable from system100. Furthermore, power source106may be of any suitable size and shape.

Particular embodiments of system100may be lightweight. As used herein, the term “lightweight” is used to refer to a weight less than 100 pounds. Some embodiments of system100may be operable to generate 100 Watts or more of power, which may be suitable for multiple application. For example, in particular embodiments, system100is capable of cutting or melting metal at distances greater than 100 meters, generating approximately 1 kilowatt per square centimeter of power at impact with the target. As another example, certain embodiments of system100may imitate a plasma or welding torch at a distance of 300 meters from a target. As yet another example, some embodiments of system100may be used to ignite incendiary material at distances of 1000 meters or greater from a target—even through certain materials (e.g., glass or lexan). One additional example is that certain embodiments of system100may also serve to disable targets by, for example, blinding with an infrared or camera system from a large distance (e.g., 5,000 meters or greater).

FIG.4illustrates a flowchart describing a method400for emitting a high-powered laser. The method400begins at a step405and proceeds to a step410. At step410, the method includes generating a laser using at least one diode mounted to a cooling plate. As discussed above with reference toFIG.1, the laser may be generated as a result of the at least one diode receiving a control signal from control processing hardware114. After generating the laser, the method400may proceed to a step415. At step415, the method includes releasing a pressurized fluid in a tank. As discussed above with reference toFIG.1, the fluid may be released from tank by opening one or more valves112. The opening of the valves may be performed upon receiving a control signal, which in some embodiments, is automatic and occurs in response to determining that a temperature of system100has reached or exceeded a threshold. As explained with respect toFIG.2, the pressurized fluid released from the tank may be a gas and, in particular, may be CO2. After releasing the pressurized fluid from the tank, the method400may proceed to a step420. At step420, the method includes directing the pressurized fluid through a manifold to a channel of a cooling plate. By directing the pressurized fluid to the channel of the cooling plate, the method causes heat transfer to occur between the cooling plate and the fluid.

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, this disclosure recognizes that a portable high-powered laser can also be cooled passively rather than active cooling by way of, for example, cooling apparatus200. In such an embodiment, system100would not require tank108and/or ancillary componentry facilitating the flow of fluid into diffusion device118(e.g., valves112, valve orifice202, manifold116). In such embodiment, passive cooling may be facilitated by components within or surrounding diodes102(e.g., metal in diode(s)102; mounting structures for diode(s)) absorbing and releasing excess heat. Such an embodiment may be suitable for applications where the portable high-powered laser is only activated for short durations of time.

Elements of different implementations described herein may be combined to form other implementations not specifically set forth above. Elements may be left out of the processes, structures, and systems described herein without adversely affecting their operation. Furthermore, various separate elements may be combined into one or more individual elements to perform the functions described herein. Although certain example embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.