Compact Laser Module with Integrated Cooling Circuit
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Solution Overview
Problem
High-power laser modules are expensive and bulky due to the need for extensive cooling systems, which require large spaces for hoses, heat exchangers, and separate cooling circuits, making them costly and time-consuming to assemble.
Innovation Solution
A compact laser module design with plug-in connections for coolant-carrying components, integrated coolant channels, and a centralized cooling system that includes a centrifugal pump and water-air heat exchanger, eliminating the need for external hoses and additional cooling circuits, and integrating the power supply's cooling into the main circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional separate cooling circuits with hoses and heat exchangers are used for high-power lasers, then effective cooling is achieved, but the system becomes bulky, expensive, and time-consuming to assemble
Solution Approach 1:
The patent merges the cooling circuit components (coolant channels, heat exchanger, pump) directly into the housing structure. The housing serves dual purposes: mechanical protection and thermal management. This integration eliminates the need for separate hoses and external heat exchangers, reducing assembly steps while maintaining cooling effectiveness through directly integrated coolant flow paths.
Solution Approach 2:
The housing is designed as a multi-functional component that simultaneously provides structural support, mechanical protection, and thermal management functions. The coolant channels are integrated into the housing walls, allowing the housing to serve as both a structural enclosure and a heat dissipation system, thereby reducing overall system complexity.
2Temperature
If traditional separate cooling circuits with hoses are used, then cooling function is provided, but assembly time increases due to hose attachment requirements
Solution Approach 1:
The cooling channels are merged into the housing structure during manufacturing, eliminating the need for separate hose installation steps. The housing is produced with integrated coolant flow paths, so no additional assembly operations are required to attach cooling components, significantly reducing assembly time while maintaining full cooling functionality.
3Temperature
If traditional separate cooling circuits are used, then cooling capacity is sufficient, but space requirements increase due to hoses and external components
Solution Approach 1:
The cooling channels are nested within the housing walls, with coolant flow paths embedded in the structural material. The heat exchanger and pump are integrated into the housing volume rather than occupying external space. This nesting approach maintains sufficient cooling capacity while minimizing the overall footprint of the system.
Solution Approach 2:
Multiple functions (structural support, cooling channels, heat dissipation) are merged into the housing volume, eliminating the need for separate external cooling components and hoses that would increase space requirements. The integrated design maintains cooling capacity while reducing the total area occupied by the system.
4Temperature
If multiple separate cooling circuits are used for laser and power supply, then each component is cooled effectively, but system cost increases
Solution Approach 1:
The patent merges the cooling circuits for the laser and power supply into a single integrated system. The housing contains unified coolant channels that provide cooling to both components through a common fluid circuit, eliminating the need for separate cooling systems and reducing manufacturing costs associated with multiple independent cooling assemblies.
Solution Approach 2:
The housing is designed as a universal thermal management system that simultaneously cools multiple components (laser, power supply) through integrated coolant channels. This multi-functional approach replaces multiple separate cooling systems with a single cost-effective solution that maintains effective cooling for all heat-generating components.
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 reduces assembly time and space requirements, ensures efficient cooling, and allows for a more compact and cost-effective setup of high-power laser modules, while maintaining effective heat dissipation without the need for additional cooling infrastructure.
Implementation Method 1
Both components of the laser cavity are housed in a housing through which the coolant flows. The laser cavity is consequently completely surrounded by the coolant.
Implementation Method 2
In order to be able to dissipate the heat from the coolant circuit again, a fan and a water/air heat exchanger are provided.
Implementation Method 3
A centrifugal pump is advantageously used as the pump
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a laser module comprising a laser source (2), a power supply (3), and a cooling device, wherein the cooling device includes a coolant circuit with a reservoir (1), a pump (5), and a heat exchanger (6). According to the invention, all components form a compact unit, and all coolant-carrying parts are integrated into the coolant circuit via push-fit connections without hoses.