Dual-Function Optical Bench and Cooling Manifold for High-Power Laser Systems
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Solution Overview
Problem
Conventional high-power laser systems face challenges in maintaining precise optical alignment due to temperature variations in the optical bench, which can cause deformation and misalignment of critical components, especially at higher average powers where size and weight become significant issues.
Innovation Solution
A dual-function optical bench and cooling manifold that provides coolant to the laser diode pump arrays and pumphead, allowing for partial deformation during operation while maintaining optical alignment by coupling the pumphead housing to the input and output optics, and is designed to thermally balance the system to minimize misalignment of critical optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate cooling system is used to cool laser components, then cooling effectiveness is improved, but the optical bench must be maintained in an isothermal state which prevents thermal management flexibility and complicates the system structure
Solution Approach 1:
The patent combines the optical bench and cooling manifold into a single integrated structure. The optical bench serves dual functions as both a mechanical support platform and a thermal management system, with coolant channels embedded within the bench itself to provide direct cooling to laser components while maintaining structural support functions.
Solution Approach 2:
The optical bench is designed to perform multiple functions simultaneously: providing mechanical support for optical components, serving as a thermal conduction path for heat removal, and acting as a structural framework for the laser system. This multi-functionality eliminates the need for separate cooling systems and reduces overall system complexity.
2Reliability
If the optical bench is maintained in an isothermal state to prevent deformation, then optical alignment stability is improved, but the ability to efficiently manage heat from high-power laser components is reduced
Solution Approach 1:
The optical bench is designed with non-uniform thermal properties in different regions. Areas with high heat generation from laser components have enhanced cooling capabilities and higher thermal conductivity, while other regions maintain lower thermal conductivity to minimize thermal deformation. This spatial variation in thermal properties allows efficient heat removal from critical areas while maintaining overall dimensional stability.
Solution Approach 2:
The patent employs materials and design features that change thermal parameters across the optical bench. The cooling manifold integrates thermal conduction paths with varying cross-sections and materials to create controlled thermal gradients, allowing the bench to conduct heat away from laser components while limiting thermal expansion and deformation in critical optical alignment regions.
3Loss of energy
If high-power laser components are cooled through the optical bench, then heat removal is improved, but thermal deformation of the optical bench occurs which affects optical alignment
Solution Approach 1:
The optical bench is designed to accommodate controlled thermal deformation through dynamic compensation mechanisms. The structure includes compliant elements and adjustable mounting features that allow the bench to thermally expand and contract in predictable ways while maintaining optical component alignment through active or passive compensation systems.
Solution Approach 2:
The system incorporates temperature sensors and alignment monitoring that provide feedback to control systems. This feedback enables real-time adjustment of cooling rates, component positions, or bench temperature distribution to maintain optimal optical alignment even as thermal conditions change during high-power operation.
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
This design maintains linear and angular alignment between critical components along critical axes, accommodating thermal expansion and contraction, and allows for efficient cooling, reducing the size and weight of the system while maintaining high-power laser performance.
Implementation Method 1
The optical bench and cooling manifold is configured to provide coolant to the one or more laser diode pump arrays and the pumphead through the optical bench and cooling manifold
Implementation Method 2
The optical bench and cooling manifold is configured to provide coolant to the one or more laser diode pump arrays and the pumphead through the optical bench and cooling manifold
Implementation Method 3
The optical bench and cooling manifold is configured to partially deform during operation of the laser system
Data Source
AI summary
A system includes a laser system having a master oscillator and a planar waveguide (PWG) amplifier having one or more laser diode pump arrays, a pumphead, input optics, and output optics. The system also includes an optical bench and cooling manifold coupled to the pumphead. The optical bench and cooling manifold is configured to provide coolant to the one or more laser diode pump arrays and the pumphead through the optical bench and cooling manifold. The optical bench and cooling manifold is also configured to partially deform during operation of the laser system. A housing of the pumphead is coupled to the input and output optics to maintain optical alignment of the pumphead with the input and output optics.