Stackable Laser Beam Module Assembly for Scalable Power
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Solution Overview
Problem
Conventional laser devices are limited by their narrow scope, high cost, and lack of adaptability, making them unsuitable for mass production and diverse applications, particularly due to their reliance on single or few high-power laser sources, which are expensive and scarce, and are not failure-tolerant, restricting their use to specialized applications.
Innovation Solution
A modular laser system that combines multiple lower-power laser sources through a stackable beam module assembly using recursive coupling of converging and diverging lenses, allowing for proportional power increase and continued operation even in the event of a laser source failure, with the ability to link standard components for scalable and cost-effective configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional laser systems use one or few high-power laser sources to achieve maximum power output, then the power output is sufficient for industrial applications, but the cost increases exponentially and component availability decreases
Solution Approach 1:
The patent divides a single high-power laser system into multiple lower-power laser modules that can be combined. Instead of using one or few expensive high-power laser sources, the system employs multiple standard-power laser sources (e.g., 500W modules combined to achieve 2kW output) that are cheaper, more available, and can be manufactured at scale. This segmentation resolves the contradiction by achieving high power output through aggregation of affordable components rather than relying on scarce high-power sources.
Solution Approach 2:
The patent combines multiple lower-power laser beams into a single high-power output beam using optical combining techniques. Multiple laser sources operating at standard power levels are merged through beam combining optics to produce the equivalent output of a single high-power source, thereby achieving high power output while using inexpensive, readily available components.
2Device complexity
If conventional laser systems use single or few laser sources to reduce device complexity, then the system structure is simple, but the reliability decreases significantly when a laser source fails
Solution Approach 1:
The patent segments the laser system into multiple independent laser source modules, each capable of operating autonomously. This segmentation enables failure tolerance because if one module fails, the others continue to operate and can be individually replaced without shutting down the entire system. The modular architecture resolves the contradiction by distributing risk across multiple independent units rather than concentrating it in a single source.
Solution Approach 2:
The patent changes the operational parameter from single-source continuous operation to multi-source redundant operation. By configuring multiple laser sources to operate in parallel with the ability to independently activate or deactivate individual sources, the system achieves both manageable complexity and high reliability through parameter-based redundancy.
3Device complexity
If conventional laser systems use fixed configurations with limited number of laser sources, then the device complexity is low, but the adaptability to different applications and power levels is restricted
Solution Approach 1:
The patent segments the laser system into standardized, interchangeable modules that can be configured in different numbers and arrangements. Each module is a self-contained unit with standard interfaces, allowing the system to be adapted to various power requirements by simply adding or removing modules. This segmentation enables versatile adaptability while maintaining relatively simple individual module designs.
Solution Approach 2:
The patent designs universal laser modules that can serve multiple applications and power levels through standardized interfaces and configurations. The same basic module design can be used across different applications by varying the number of modules combined, making the system universally adaptable without requiring complex reconfiguration or specialized components for each application.
4Power
If conventional laser systems use high-power laser sources to achieve desired power output, then the power output is sufficient, but the efficiency decreases due to duty cycle modulation requirements
Solution Approach 1:
The patent segments the power delivery function across multiple laser sources operating in parallel. Instead of modulating a single high-power source on and off (duty cycling), multiple sources operate continuously at optimal efficiency points, with the aggregate output providing the desired power level. This segmentation eliminates the need for inefficient duty cycle modulation while achieving the same overall power output.
Solution Approach 2:
The patent enables continuous operation of multiple laser sources at their optimal efficiency points rather than intermittently modulating a single source. By distributing the power delivery across multiple continuously operating sources, the system maintains continuous useful action at peak efficiency, avoiding the energy losses associated with duty cycle modulation.
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 modular system enables adaptable, cost-effective, and reliable laser devices with scalable power output, suitable for various applications, from soft materials to heavy industrial uses, while maintaining performance and reducing component costs and availability issues.
Implementation Method 1
a converging lens affixed within the central beam channel such that an optical plane of the converging lens is in generally perpendicular alignment with the longitudinal axis of the housing
Implementation Method 2
a diverging lens affixed within the central beam channel such that an optical plane of the diverging lens is in generally perpendicular alignment with the longitudinal axis of the housing
Implementation Method 3
typically employ reflective surfaces for directing trajectories of secondary beams onto a common beam path
Data Source
AI summary
A stackable beam module assembly and system for combining laser beams by recursive coupling of one or more beam modules whereby successive converging and diverging lenses having optical properties and an orientation in central beam channels and peripheral beam channels to direct the peripheral beams in a direction parallel to the central beams to thereby propagate a resultant beam having an increased power output directly correlated to the sum of the combined laser beams.