Downhole Diode Laser Drilling System With Thermal Management
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Solution Overview
Problem
Current methods for delivering high power laser energy to deep boreholes, particularly through hard rock formations like granite and basalt, are inefficient and costly, with existing mechanical drilling methods being less effective compared to the desired laser drilling capabilities.
Innovation Solution
A high power laser drilling system is developed, comprising a source of high power laser energy, a tubing assembly, and a cooling system, with the ability to convey the laser source and fluid downhole, utilizing a plurality of diode lasers and a cooling system that maintains the laser temperature below 50°C, enabling efficient drilling through various rock types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high power laser energy is delivered to deep boreholes through hard rock formations, then drilling efficiency and drilling rate are improved, but system complexity and cost increase
Solution Approach 1:
The system segments the high power laser source into multiple individual diode laser units that can be independently managed and combined. This modular approach allows the system to achieve high power output while maintaining manageable complexity through standardized, replaceable components rather than a single complex laser source.
Solution Approach 2:
The patent implements a nested structure where multiple diode laser units are housed within a common housing or module assembly. The lasers are arranged in an array configuration within the confined space, allowing compact integration of multiple functional elements while maintaining individual accessibility for maintenance and replacement.
2Power
If multiple diode lasers are used to generate high power laser beams, then laser power is improved, but heat generation increases
Solution Approach 1:
The patent combines multiple diode laser units into a single integrated array system where the individual laser elements work together to generate high power output. The cooling system is similarly merged as a unified thermal management solution that serves all laser units simultaneously, efficiently removing heat from the entire array rather than requiring separate cooling systems for each laser.
Solution Approach 2:
The patent introduces a working fluid as an intermediary medium that facilitates heat transfer from the laser diodes to the cooling system. This fluid circulates through channels in direct thermal contact with the laser units, absorbing heat and transporting it away from the laser elements to external heat exchangers, thereby maintaining optimal operating temperatures.
3Reliability
If cooling system is implemented to maintain laser temperature below 50°C, then laser reliability is improved, but system complexity increases
Solution Approach 1:
The cooling system is designed to be self-regulating and automatically maintain laser temperatures within the required range. The system uses natural convection currents and thermal expansion principles to circulate the working fluid without requiring complex external pumps or control mechanisms, thereby achieving reliable temperature control while minimizing system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively delivers high power laser energy to the bottom of deep boreholes, enhancing drilling efficiency and cost-effectiveness by providing a superior drilling rate through hard rock formations compared to conventional mechanical methods.
Implementation Method 1
a cooling system that maintains the laser temperature below 50°C
Implementation Method 2
delivering high power laser energy to perform laser operations, including drilling, welding, cutting and cladding operations
Data Source
AI summary
Systems, apparatus and methods for performing laser operations in boreholes and other remote locations, such operations including laser drilling of a borehole in the earth. Systems, apparatus and methods for generating and delivering high power laser energy below the surface of the earth and within a borehole. Laser operations using such downhole generated laser beams.