High Power Laser Beam Plasma Channel Standoff Distance

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Solution Overview

Problem

There is a long-standing need for delivering high power laser beams over distances, particularly through free space, to effectively perform laser operations such as cutting, drilling, and material processing without significant power loss.

Innovation Solution

The method involves directing a high power laser beam with a power of at least 1 kW in a predetermined three-dimensional pattern to remove material along that pattern, creating directed energy affected areas that occupy a specific volumetric shape, and minimizing the need for mechanical cleaning or fluid jets to remove the affected material, allowing for long stand-off distances and reduced mechanical intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If high power laser beams are delivered over long distances through free space, then the ability to perform laser operations in remote locations is improved, but significant power loss occurs

Engineering Contradiction:

Improvestand-off distanceVSAvoidpower loss

Core Design Contradiction:

Length of moving objectVSLoss of energy

Solution Approach 1:

The patent changes the physical parameters of the laser beam by transforming it into a plasma channel that guides the beam energy. This plasma-mediated transmission allows the laser energy to be delivered over long distances with minimal power loss by maintaining the beam's coherence and intensity through the plasma waveguide effect

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces plasma as an intermediary medium between the laser source and the target material. The plasma channel acts as a mediator that transports the laser energy over extended distances while preserving its high power characteristics, enabling effective laser operations at stand-off distances that would otherwise result in significant power loss

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If high power laser beams are focused to a small spot size for precise material processing, then manufacturing precision is improved, but the depth of focus is reduced

Engineering Contradiction:

Improvespot sizeVSAvoiddepth of focus

Core Design Contradiction:

Manufacturing precisionVSLength of stationary object

Solution Approach 1:

The patent employs dynamic focusing through plasma channel formation where the plasma density and length can be adjusted in real-time. This allows the system to adapt the depth of focus dynamically while maintaining a small spot size at the target, resolving the trade-off between precision and working depth by making the optical system adaptable to different processing requirements

Inventive Principle:

Principle #15Dynamics

3Productivity

If mechanical cleaning or fluid jets are used to remove affected material, then material removal efficiency is improved, but device complexity and mechanical intervention increase

Engineering Contradiction:

Improvematerial removal efficiencyVSAvoidmechanical cleaning requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical cleaning systems and fluid jet apparatus with a purely optical-plasma based material removal mechanism. The high power laser plasma channel directly ablates and vaporizes the affected material, eliminating the need for separate mechanical cleaning or fluid assistance systems while maintaining high material removal efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enables efficient and precise laser operations at extended distances with reduced material removal complexity, facilitating applications in various fields like mining, construction, and remote locations without the need for extensive mechanical support or fluid assistance.

Implementation Method 1

delivering high power laser beams over distances to a work surface to perform a laser operation on the work surface

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

applying high power directed energy having a power sufficient to penetrate the material in a predetermined three dimensional pattern

Methodology Applied

Scientific EffectDirected energy:

Implementation Method 3

removing the material along the three dimensional pattern

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS9545692B2Long stand off distance high power laser tools and methods of use

Publication Date: 2017.01.17 FORO ENERGY INC

AI summary

There are provided high power laser cutting tools, optics assembly and laser beam configurations having long stand off distances, which provide high power laser beams, greater than 1 kW, to cut and volumetrically remove targeted materials. There is also provided methods of using these tools using a beam delivery angle that provides for molten material to be removed by flowing out of the targeted material.