Description:4. DESCRIPTION
Technical Field of the Invention

The present invention relates to the field of electronics and communications, specifically focusing on laser communications. More precisely, it relates to a laser unit that engages with a target unit to provide simulated training exercises for army soldiers.

Background of the Invention

Laser systems have found widespread use in various fields, including military training, medical procedures, and industrial applications, due to their high precision, reliability, and ability to focus on small targets. However, despite their advantages, one of the primary challenges associated with laser-based systems is the inability to effectively merge multiple laser beams—specifically visible and infrared (IR) lasers—into a single, coherent output beam that retains the high accuracy and efficiency of both beams. This is a critical issue, as different wavelengths serve distinct purposes. Visible lasers are often used for targeting, while IR lasers are used for tracking, sensor feedback, or night-time operations. The challenge becomes particularly acute in systems that require both types of lasers to be merged into a single output beam for precise targeting over extended distances.

In military applications, for example, laser-based simulators are often used for marksmanship training and other combat simulations. These simulators typically require both visible and infrared laser sources. The visible laser is used for targeting and visibility, while the IR laser provides tracking and sensor feedback. In these systems, the critical issue lies in merging the two beams into a unified, precise output that can be targeted accurately. The ability to merge visible and IR laser beams into a single, coherent beam for accurate targeting is thus essential for realistic and effective training, which existing systems often fail to achieve due to limitations in their beam alignment and merging mechanisms.

In other industries, such as medical procedures or industrial applications, the need for integrating visible and IR beams into a single laser output is equally vital. For instance, in laser surgeries or diagnostic procedures, high precision is required to target specific areas while minimizing collateral damage. In industrial environments, laser alignment systems and measurement devices rely on laser beams for precise positioning or inspection. The current systems often lack the necessary accuracy, adaptability, and precision to meet the demands of these critical applications.

The need for laser beam merging has been addressed in various ways in prior art, but each solution has its limitations. Several prior patents have attempted to improve laser alignment and beam control, yet few have successfully addressed the challenge of merging visible and IR beams into a single, coherent beam with the required precision for high-accuracy targeting.

For example, US20120171643A1 describes an alignment device that ensures precise alignment between a simulation beam and the sight of a weapon. The device includes a housing with an optical receiving port, but it focuses only on the alignment between beams and the sighting axis, without merging visible and IR laser beams into a unified output for precise targeting. While effective in alignment, this system does not address the merging of multiple beams into a single, coherent beam.

Similarly, US20150377588A1 describes a system for aligning laser and optical systems over long distances using reflective materials. Although it improves alignment accuracy, it fails to merge visible and IR lasers, leaving the system inadequate for applications that require both types of lasers to be integrated seamlessly for a unified beam.

US20180259295A1 presents a laser device for firearm aiming that includes a laser diode capable of emitting multiple wavelengths. However, this invention does not provide a solution for merging the visible and IR beams into a single, coherent beam. The lack of beam merging capability restricts the application of this system in environments where both visible and IR lasers need to work in tandem, such as military training and other high-precision applications.

Additionally, US6887079B1 discusses an alignment device for synchronizing a weapon and a weapon-mounted simulator. The system uses an alignment beam to synchronize the simulator with the weapon’s sight. However, this prior art is limited to alignment and does not address the challenge of merging visible and IR lasers into a single, unified output. It focuses on beam alignment but lacks the critical beam integration needed for applications requiring combined visible and IR laser outputs for precise targeting.

These prior art systems, while useful in specific contexts, do not provide a solution to the problem of effectively merging visible and IR laser beams into a single, coherent beam with the necessary precision and control for accurate targeting in dynamic environments. The existing systems typically focus on beam alignment or individual beam control, but they fall short in providing a unified beam that integrates both wavelengths without compromising performance.

Despite the advancements in the field of laser technology, there are several significant disadvantages in the prior art that hinder the development of high-performance integrated laser units. These limitations primarily concern the inability to merge visible and IR laser beams effectively, and the lack of precise, flexible, and adaptable beam control mechanisms.

One of the major drawbacks of existing systems is the lack of integration between visible and IR laser beams. Most prior art solutions rely on separate beams for different wavelengths, which introduces complexity in targeting and alignment. The need for a single, unified beam output that combines both visible and IR lasers is critical for many high-precision applications. The inability to merge these beams effectively results in a fragmented system that cannot offer the same level of precision and efficiency as an integrated system.

Another disadvantage is the limited flexibility and range of beam control offered by traditional systems. Existing systems often rely on fixed alignment mechanisms that are rigid and lack the adjustability needed for precise directional control. For example, the ability to adjust the beam’s direction in both the horizontal and vertical axes is essential for targeting in different environments or conditions. Many prior art systems provide only one-dimensional adjustments, which severely limits their applicability in dynamic or real-world scenarios where fine-tuned beam direction control is required.

Furthermore, prior systems often struggle to maintain beam precision under changing environmental conditions. Factors such as temperature fluctuations, humidity, and physical movement can affect the alignment and performance of the laser beams. This environmental sensitivity can lead to inaccurate targeting and poor system performance, making these prior systems unsuitable for real-world applications where conditions may vary over time or in unpredictable ways.

Finally, traditional laser systems are often complex and cumbersome. Many of the prior art systems involve multiple components that need to be individually calibrated and adjusted. This complexity increases the maintenance overhead and the time required to set up and calibrate the system, which can be a significant drawback in applications where quick setup and consistent performance are crucial.

There is an urgent need for a new and improved integrated laser unit (ILU) that can seamlessly merge visible and infrared laser beams into a single, coherent output for high-precision targeting. The inability to merge these beams effectively in prior art systems has led to inefficiencies and limitations in various industries, including military, medical, and industrial fields. An integrated solution that offers precise beam merging and flexible beam direction control is critical for enhancing targeting accuracy and improving operational efficiency.

In military training, the ability to merge visible and IR lasers into a single beam would significantly improve the realism and effectiveness of laser-based simulators. High-precision laser simulators are essential for training soldiers in marksmanship, target engagement, and combat simulations, but current systems often lack the ability to accurately combine laser beams for precise targeting. A unified laser system would provide the accuracy and realism needed for effective training in dynamic environments.

In the medical field, where laser surgeries and diagnostic procedures require extreme precision, the ability to merge visible and IR lasers into a single output beam could improve outcomes by enabling more accurate targeting. Similarly, in industrial applications, where lasers are used for alignment, measurement, and inspection, the need for high-precision systems that can merge beams effectively is growing. The lack of precision in existing systems limits their utility in these high-stakes environments.

Moreover, the invention addresses the need for a simplified, adaptable system that operates efficiently under a wide range of environmental conditions. The prior art systems that are sensitive to temperature, humidity, and movement fail to meet the standards of real-world operations. A robust system that can perform consistently in various conditions is not just desirable but essential in industries where reliability and precision are paramount.

The integrated laser unit proposed by this invention promises to fill this gap by merging visible and infrared laser beams into a single, high-precision output, with enhanced beam direction control, and the flexibility to operate in changing environments. The simplicity, reliability, and accuracy of this integrated system will significantly improve the performance and applicability of laser-based technologies across several critical industries.

Objects of the Invention

The primary object of the present invention is to provide an integrated laser unit (ILU) capable of merging visible and infrared (IR) laser beams into a single, coherent output beam for high-precision targeting. The system ensures that the visible and IR beams are combined in such a way that they maintain their individual characteristics while achieving a unified output with minimal divergence. This innovation is critical for applications where precise beam direction control and high accuracy are essential, particularly in military, medical, and industrial environments.

Another object of the invention is to offer precise alignment and minimal beam divergence through the use of a compliant monolithic structure. This structure supports both the visible laser mirror and the long pass filter, allowing for fine adjustments in at least two degrees of freedom (DOF). These adjustments ensure that the visible and IR laser beams are properly aligned, preventing any divergence that could impair the system’s precision. By enabling these fine adjustments, the system guarantees that the laser beams merge with optimal efficiency, producing a single, coherent output beam that can be accurately aimed.

A further objective is to provide adaptable and adjustable beam direction control for both horizontal and vertical axes. The system integrates azimuth and elevation steering mirrors that allow for fine adjustments of the output beam along both axes. This level of control is necessary to achieve high-precision targeting, ensuring that the merged beam can be directed with accuracy and flexibility. Whether targeting fixed or moving objects, the system can be calibrated to maintain precision in both directions.

The invention also seeks to ensure that the integrated laser unit can perform effectively under a variety of environmental conditions. Traditional laser systems often struggle with precision in dynamic environments where factors like temperature fluctuations, humidity, and movement can affect the accuracy of beam alignment. This system is designed to be robust, maintaining high-accuracy targeting despite these variables, thus making it suitable for real-world applications where environmental stability is not guaranteed.

Finally, the invention aims to simplify the overall system design while maintaining high-performance standards. Traditional laser systems often require complex arrangements of components that can be cumbersome to assemble, calibrate, and maintain. By integrating the beam steering and merging mechanisms into a single unit, the present invention offers a streamlined solution that reduces system complexity, increases efficiency, and improves usability without compromising on precision or performance.

Brief Summary of the Invention

The present invention is an integrated laser unit (ILU) designed to merge visible and infrared (IR) laser beams into a single, coherent output beam for high-precision targeting. The system comprises a visible laser source and an IR laser source, both of which emit their respective beams. These beams are directed towards a long pass filter, which transmits the IR beam while reflecting the visible laser beam, thereby merging both into a single output. This integration allows the system to produce a highly accurate beam suitable for applications requiring precision alignment and targeting.

The system utilizes a visible laser mirror positioned at a 45-degree angle to the visible laser source, ensuring that the visible laser beam is directed properly toward the long pass filter. The long pass filter plays a critical role in merging the beams, as it selectively transmits and reflects specific wavelengths to combine the two beams effectively. A compliant monolithic structure supports both the visible laser mirror and the long pass filter, allowing for precise adjustments in multiple degrees of freedom. This structure ensures that the beams are correctly aligned, preventing misalignment and reducing the risk of divergence that could affect the accuracy of the merged beam.

The invention also features azimuth and elevation steering mirrors, which allow for horizontal and vertical adjustments of the output beam. These mirrors are positioned downstream of the merged beam and are supported by a multi-axis adjustable frame. This frame facilitates independent and simultaneous adjustments of the steering mirrors, ensuring that the merged beam is directed with high accuracy. These steering mirrors provide precise control over the beam’s direction, enabling the system to perform well across a wide range of operational conditions.

In addition to the mechanical components, the system includes an electronic control system that provides real-time feedback on the orientations of the azimuth and elevation mirrors. This system enables automated adjustments based on operational parameters or user input, allowing the system to maintain accurate beam alignment even in dynamic or unpredictable environments. This ensures that the integrated laser unit remains adaptable and highly accurate in various application scenarios.

Advantages of the Invention

The primary advantage of the present invention lies in its ability to merge visible and infrared laser beams into a single, coherent output with minimal divergence. This unique capability provides a level of precision targeting that is difficult to achieve with traditional systems that often rely on separate beams. By combining the two beams into a unified output, the system ensures higher accuracy, making it ideal for applications where precision is critical, such as military training, medical procedures, and industrial processes.

Another key advantage is the adaptability and flexibility of the system. The integration of azimuth and elevation steering mirrors allows the system to provide fine control over beam direction along both horizontal and vertical axes. This ability to adjust the output beam ensures that the system can be used in a wide range of applications, from targeting moving objects to precision alignment in industrial setups. The multi-axis adjustable frame further enhances the system’s versatility, providing independent and simultaneous adjustments that allow for high-accuracy targeting across diverse conditions.

The invention also offers significant robustness in challenging environments. Unlike traditional laser systems, which often struggle with beam accuracy in dynamic or variable conditions, this integrated laser unit has been specifically designed to function reliably even under changing environmental factors such as temperature fluctuations, humidity, or physical movement. This feature makes the system particularly valuable in military applications or field operations, where precision must be maintained despite external disruptions.

Furthermore, the design of the system is streamlined, reducing complexity while maintaining high precision and performance. Traditional laser systems may involve multiple components that must be manually aligned and adjusted. The present invention integrates these components into a single unit, simplifying the assembly and calibration process. This simplified design makes the system easier to operate, maintain, and adjust, resulting in reduced overhead and greater operational efficiency.

Applications of the Invention

The integrated laser unit has numerous practical applications across various industries. One of the most significant applications is in military training, where the system can be used for realistic marksmanship simulations. The high-precision beam merging and direction control capabilities make it ideal for military training exercises that require accurate laser targeting without the risk of live ammunition. The system can simulate real-world combat scenarios, helping soldiers develop their targeting skills in a controlled and safe environment.

In the medical field, this invention could be used for laser-based surgeries or diagnostic procedures, where precise targeting of tissues or organs is required. The high-accuracy output beam could facilitate operations such as laser cutting, laser ablation, or biopsy guidance, where precise control is essential to minimize damage to surrounding tissues.

The system also has potential industrial applications in areas such as alignment, measurement, and inspection. For instance, it can be used in laser alignment systems for machinery or to inspect the alignment of parts in manufacturing processes. The flexibility in beam direction and the ability to merge different wavelengths make it adaptable to various precision tasks, ensuring that it can be used in high-performance industrial systems.

Brief Summary of the Drawings

The invention will be further understood from the following detailed description of a preferred embodiment taken in conjunction with an appended drawing, in which:

Fig. 1 illustrates an integrated laser unit with merged visible and infrared beams in accordance with the exemplary embodiment of the present invention.

Fig. 2 illustrates systematic flow of visible and invisible beams disclosing beam merging in accordance with the exemplary embodiment of the present invention.

It is appreciated that not all aspects and structures of the present invention are visible in a single drawing, and as such multiple views of the invention are presented so as to clearly show the structures of the invention.

Detailed Description of the Invention

The exemplary embodiment of the present invention provides an integrated laser unit (ILU) designed to merge visible and infrared (IR) laser beams into a single, coherent output beam for high-precision targeting. The system is engineered to integrate the two different laser sources in such a way that the merged beam can be directed with high accuracy, ensuring precise targeting in various applications, particularly in military training, medical procedures, and industrial processes. The ILU is composed of several key components that work in tandem to achieve the desired functionality, all integrated into a compact and efficient unit.

The system includes two primary laser sources, a visible laser source and a pulsed IR laser source, each of which emits laser beams of distinct wavelengths. The visible laser source is configured to emit a visible laser beam that is detectable by the human eye, allowing for targeting and alignment during training exercises or other applications. The IR laser source, on the other hand, emits a pulsed infrared beam that is used primarily for tracking or sensor feedback. The primary challenge addressed by this invention is the merging of these two beams into a single, coherent output while maintaining the individual properties of each beam.

The visible laser beam emitted from the visible laser source is directed towards a visible laser mirror. This mirror is positioned at a 45-degree angle relative to the laser source and is configured to reflect the visible laser beam towards a long pass filter. The function of the visible laser mirror is to ensure that the visible laser beam is properly directed toward the long pass filter, where the critical process of beam merging occurs. The long pass filter is a key component in this system. It is specifically designed to transmit the IR laser beam while reflecting the visible laser beam, thus effectively merging the two beams into a single output. The long pass filter plays a crucial role in ensuring that the merged beam maintains the desired characteristics of both the visible and IR lasers without causing distortion or loss of energy.

The long pass filter is positioned along the optical path of the two laser beams, and it reflects the visible laser beam while allowing the IR laser to pass through. This ensures that both beams are merged into a single output beam that contains the characteristics of both the visible and IR wavelengths. This integration is essential in various applications, such as in military training simulators, where both visible and infrared lasers are used to engage and track targets, or in medical procedures, where precision targeting is necessary.

The system also includes a compliant monolithic structure, which supports the visible laser mirror and the long pass filter. This structure allows for fine adjustments in at least two degrees of freedom (DOF), enabling precise alignment of the visible and IR laser beams. These adjustments ensure that the beams are properly aligned, minimizing divergence and ensuring that the output beam is perfectly focused. The monolithic structure also provides the mechanical stability needed for accurate beam alignment, ensuring that the laser system remains stable and reliable throughout its operation.

Once the beams are merged, the next crucial step in the system is the direction control of the output beam. This is achieved using azimuth and elevation steering mirrors. The azimuth steering mirror is positioned downstream of the merged output beam and is capable of horizontal adjustments, directing the beam along the horizontal axis. The elevation steering mirror is positioned downstream of the azimuth mirror and is capable of vertical adjustments, directing the beam along the vertical axis. These steering mirrors provide fine control over the direction of the output beam, enabling it to be directed to specific targets with high precision.

To ensure that both the azimuth and elevation steering mirrors are properly aligned and adjusted, the system uses a multi-axis adjustable frame. The multi-axis adjustable frame supports both the azimuth and elevation mirrors, allowing for independent and simultaneous adjustments to achieve precise beam alignment. The frame’s design ensures that the output beam can be directed with minimal divergence and high accuracy. It provides a stable base for the steering mirrors and allows for real-time adjustments, making it adaptable to various operational conditions.

In addition to the mechanical components, the system is equipped with an electronic control system. This system provides real-time feedback on the orientations of the azimuth and elevation mirrors (170, 180). The electronic control system enables automated adjustments based on operational parameters or user input. This ensures that the system can adapt to changing conditions, such as environmental variations or shifting target locations, without requiring manual recalibration.

The electronic control system plays a vital role in maintaining the system’s high-accuracy targeting capabilities. By continuously monitoring the orientations of the steering mirrors, the control system ensures that the output beam is directed precisely, regardless of external factors. This is especially important in dynamic environments, such as military or industrial settings, where quick and accurate adjustments are essential for successful operation.

The integrated laser unit described here represents a significant advancement in laser-based systems, particularly those that require precise targeting and high adaptability. The merging of visible and IR laser beams into a single output beam with minimal divergence, coupled with the ability to control the direction of the beam with high precision, makes this system suitable for a wide range of applications.

The exemplary embodiment of the present invention can be better understood by referencing the figures and reference numerals as used in the claims. The figures illustrate the system’s components and their respective interactions, providing a clear visualization of how the different elements of the integrated laser unit work together to achieve the desired functionality.

Figure 1 illustrates the system's overall architecture, highlighting the arrangement of the primary components involved in merging the visible and IR laser beams. In this figure, the visible laser beam is emitted from the visible laser source (110) and directed toward the visible laser mirror (130). The visible laser mirror reflects the beam at a 45-degree angle, directing it toward the long pass filter (140). The IR laser beam, which is emitted from the IR laser source (120), continues through the long pass filter without being reflected, as the filter is designed to transmit the IR beam and reflect the visible beam. The long pass filter (140) thus serves as the crucial element for merging both beams into a single output beam (150), which then exits the system for further manipulation or targeting.

Figure 2 provides a more detailed illustration of the beam direction control mechanism. In this figure, the merged output beam (150) is directed toward the azimuth steering mirror (170), which adjusts the beam in the horizontal direction. The azimuth mirror allows the user to adjust the beam’s horizontal position within a predetermined range. The output beam is then directed to the elevation steering mirror (180), which adjusts the beam's vertical position within another predetermined range. These steering mirrors, mounted on a multi-axis adjustable frame (160), allow for precise adjustments in both horizontal and vertical directions, ensuring accurate targeting. The fine control of the beam direction is achieved by the ability to make independent and simultaneous adjustments to both the azimuth and elevation mirrors, thus offering a flexible and adaptable beam steering solution.

The compliant monolithic structure (160), which supports the visible laser mirror (130) and long pass filter (140), is critical for maintaining the system's alignment. This structure enables fine adjustments in at least two degrees of freedom (DOF), which is essential for aligning the two laser beams before they are merged by the long pass filter. The ability to fine-tune the alignment ensures that the visible and IR beams are merged accurately, minimizing any divergence and ensuring the system’s high targeting precision.

The electronic control system (200), integrated into the design, ensures that the system operates effectively under various conditions. The real-time feedback from the system allows for automated adjustments to the azimuth and elevation mirrors (170, 180), ensuring that the system can adapt to changes in operational conditions. This feature is particularly useful in environments where dynamic conditions may affect the alignment or targeting requirements.

The interaction between all components in the integrated laser unit ensures that the system can merge the visible and IR laser beams effectively while maintaining high targeting precision. The flexibility provided by the azimuth and elevation steering mirrors, along with the fine-tuning adjustments available through the compliant monolithic structure (160), makes this system suitable for a wide range of applications, from military training to medical and industrial uses that require precise laser alignment and targeting.

Method of Manufacturing
The method of manufacturing the integrated laser unit (ILU) involves several crucial steps designed to assemble and align the various components to ensure high-precision functionality. The process begins with the preparation of the visible laser source (110) and infrared (IR) laser source (120). These laser sources are selected based on their wavelength requirements, with the visible laser operating within the 450–650 nm range, and the IR laser source operating between 850–1,100 nm. The laser diodes are then integrated into their respective casings to ensure they emit beams with the required intensity.

Once the laser sources are ready, the long pass filter (140) is fabricated. The filter is constructed from a high-quality substrate, such as BK7 glass or fused silica, which has the necessary optical properties to transmit the IR light while reflecting the visible laser light. The substrate is coated with a multi-layer anti-reflective coating (160) using advanced techniques like Ion Beam Sputtering (IBS) or Electron Beam Evaporation (EBE). This coating typically consists of silicon dioxide (SiO₂), titanium dioxide (TiO₂), and aluminium oxide (Al₂O₃) to enhance the filter’s ability to handle the different wavelengths efficiently. After the coating process, the filter is rigorously tested for optical performance to ensure that it correctly reflects visible wavelengths and transmits IR light with minimal energy loss.

Next, the visible laser mirror (130) is fabricated and positioned at a 45-degree angle relative to the visible laser source (110). This mirror is designed to reflect the visible laser beam toward the long pass filter (140). The mirror is mounted using precise adjustable mechanisms, ensuring that the reflected beam aligns correctly with the filter to ensure proper beam merging.

The core component of the system, the compliant monolithic structure (160), is then constructed. This structure is typically made from aluminum or stainless steel, selected for its durability and lightweight properties. It is designed to provide mechanical support for the visible laser mirror (130) and long pass filter (140), ensuring that these components can be finely adjusted in at least two degrees of freedom (DOF). This level of adjustability is crucial for aligning the two beams precisely before they are merged by the long pass filter.

Once the beam merging components are in place, the next step involves the assembly of the azimuth steering mirror (170) and elevation steering mirror (180). These mirrors are designed to adjust the direction of the merged laser beam. The mirrors are mounted on a multi-axis adjustable frame (190), which provides stability and allows for independent adjustments to achieve the desired beam direction. The mirrors are precisely aligned to allow horizontal and vertical adjustments, ensuring that the merged beam can be aimed at specific targets.

The electronic control system (200) is integrated into the unit at this stage. This system is responsible for providing real-time feedback on the orientation of the azimuth and elevation mirrors (170, 180). It also allows for automated adjustments based on input parameters or operational conditions. The control system ensures that both steering mirrors are aligned correctly, allowing the merged beam to be directed with high accuracy.

After all components are assembled, the system undergoes a rigorous calibration process. The alignment of the visible and IR laser beams is verified to ensure that the long pass filter correctly merges the two beams. The system’s beam steering mechanism is tested for precision, ensuring that the azimuth and elevation mirrors (170 and 180) can adjust the merged beam accurately. The electronic control system is also tested to confirm its ability to provide real-time adjustments based on environmental or operational changes.

Finally, the system is assembled into its protective casing, ensuring that all components are securely housed and shielded from external factors that could affect their performance. The unit is then packaged for distribution or deployment, ready for use in various applications such as military training, medical procedures, or industrial measurement.

Method of Use
The integrated laser unit (ILU) is versatile and can be used in a variety of applications, including military training, medical procedures, and industrial alignment tasks. The method of use ensures that the system can operate efficiently, providing high-precision targeting and beam merging for its intended purpose. The first step in using the ILU is setting it up in the desired location, depending on the application.

In military training, the ILU may be mounted on a weapon simulator or a training target. The system is powered up, and the visible laser source (110) and IR laser source (120) are activated. The visible laser beam emitted from the visible laser source is directed to the visible laser mirror (130), where it is reflected toward the long pass filter (140). The IR beam is passed through the long pass filter without reflection, ensuring that both beams merge to form a unified output beam (150). The resulting beam can be used for targeting in military exercises, where the visible part of the beam allows visibility, and the IR part is used for tracking and sensor feedback.

Once the system is powered and aligned, the azimuth and elevation steering mirrors (170, 180) are used to direct the merged beam (150) towards the intended target. The azimuth mirror (170) adjusts the beam along the horizontal axis, while the elevation mirror (180) adjusts it along the vertical axis. The system's ability to make precise adjustments ensures that the laser can be aimed at specific targets, whether they are stationary or moving.

For medical applications, the integrated laser unit is positioned in a surgical or diagnostic environment. The ILU is mounted in such a way that it can target specific areas with high precision, such as laser surgery or biopsy guidance. The long pass filter ensures that both visible and IR laser beams are merged without interference, enabling a focused and accurate beam to be used for procedures that require minimal disruption to surrounding tissue.

In industrial environments, the ILU can be used for alignment, measurement, or inspection tasks. The system’s high-precision beam control makes it ideal for tasks that require accurate positioning of machinery or components. The ILU can be used to align machinery in manufacturing plants, or to inspect mechanical components for alignment accuracy during production.

During use, the electronic control system (200) continuously monitors the orientation of the azimuth and elevation mirrors (170, 180). If any adjustments are needed, the control system provides real-time feedback and makes automated adjustments to ensure the output beam remains directed at the target. This feature ensures that the ILU can maintain accuracy even in dynamic or changing environments, such as during moving target simulations in military training or in variable industrial settings.

In all applications, the multi-axis adjustable frame (190) allows for independent adjustments of the steering mirrors, enabling the system to adapt to varying conditions and ensuring that the merged beam can be directed precisely to meet the operational needs. The compliant monolithic structure (160) ensures that the system remains stable and reliable, even when subjected to external factors such as physical movement or changes in environmental conditions.

Testing Standards
The Single Eye Integrated Laser Unit (ILU) undergoes a series of rigorous tests to ensure its performance meets the required specifications for high-precision targeting. These tests are conducted to evaluate the system’s beam merging accuracy, directional control, alignment precision, and overall system reliability. The testing follows standardized protocols for optical and mechanical systems, ensuring that all components function optimally under various conditions, including tolerance stack-ups and environmental changes.

The first testing standard focuses on the beam merging accuracy of the visible and infrared (IR) laser beams. The system is designed to merge these two distinct beams into a single, coherent output beam. The test involves aligning both beams to the long pass filter (140) and checking for any misalignments or angular deviations. The accuracy of beam merging is measured by assessing the point at which the beams converge on the long pass filter. Any angular deviation beyond a threshold, such as ±0.5°, would indicate a misalignment that could affect the quality of the output beam. The test ensures that both beams are merged effectively without causing distortion or loss of power.

The second standard examines the beam steering precision of the system. The azimuth and elevation steering mirrors (170, 180) are tested for their ability to direct the merged beam both horizontally and vertically. These mirrors must adjust the beam within a predetermined range, such as ±15 degrees in the horizontal direction and ±10 degrees in the vertical direction. The test involves adjusting the mirrors and measuring the beam's deflection angle to ensure the mirrors can provide the necessary directional control with high accuracy.

Tolerance stack-up testing is also crucial to assess the system’s ability to function under manufacturing tolerances. Since the components of the ILU are manufactured with specific tolerances, it is important to test whether slight variations in manufacturing or assembly can affect the system’s overall performance. The test involves simulating the assembly of components with slight variations and checking if the alignment and beam merging are still within acceptable limits. This ensures that the system remains accurate and reliable despite small variations in component sizes or assembly.

Environmental testing is conducted to simulate real-world conditions, such as temperature fluctuations and high humidity. The system is subjected to environmental stressors ranging from -10°C to 50°C and up to 95% humidity to verify that the ILU operates correctly under various environmental conditions. This test is essential to ensure that the beam alignment and steering mechanisms do not shift or become inaccurate when exposed to extreme environmental factors. The ability of the system to remain stable in such conditions confirms its suitability for outdoor, military, and field applications.

Another testing standard involves measuring the beam divergence and focus quality of the merged laser beam. Once the visible and IR beams are merged, the system must produce an output beam with minimal divergence, ensuring that the beam stays focused over long distances. The divergence of the beam is measured, and the focus quality is assessed using a beam profiler. The system is tested at various distances to ensure the beam remains tightly focused without significant spread, which is critical for maintaining precision targeting.

The electronic control system (200) is tested for its ability to provide real-time feedback and automated adjustments. The control system monitors the orientations of the azimuth and elevation mirrors, adjusting them automatically based on operational conditions. This test ensures that the system can make real-time corrections to keep the merged beam aligned during use. The feedback loop is assessed for its accuracy and responsiveness, particularly when the beam’s direction changes dynamically, such as in military training or medical procedures where real-time adjustments are necessary.

Finally, the ILU undergoes laser safety compliance testing. The system’s output power and wavelengths are tested to ensure they meet the safety standards set by regulatory bodies such as the FDA or IEC 60825-1. The system is verified to maintain Class 1 laser safety limits, ensuring that the beam does not exceed safe power levels during operation. This test is critical to ensure that the system is safe for use in environments such as military training zones or medical facilities, where laser safety is paramount.

Experimental Results
The experimental results from the testing phase demonstrate that the Single Eye Integrated Laser Unit performs consistently well across all tested parameters. The system successfully meets the required specifications for beam merging, beam steering, environmental stability, and safety compliance.

In terms of beam merging accuracy, the system consistently achieved angular alignment within ±0.2°, well below the tolerance threshold of ±0.5°. This indicates that the visible and IR beams were effectively merged at the focal point of the long pass filter (140), producing a unified output beam (150) with minimal deviation. The alignment of the visible and IR beams was verified to be precise, ensuring that the combined beam maintains the desired properties for accurate targeting.

The beam steering precision tests showed that the azimuth steering mirror (170) and elevation steering mirror (180) could adjust the merged beam within the specified ranges. The horizontal adjustments provided by the azimuth mirror were accurate within the ±15-degree range, and the vertical adjustments provided by the elevation mirror were within ±10 degrees. These results confirm that the system offers flexible and precise control over the direction of the merged laser beam, allowing for accurate targeting in both horizontal and vertical planes.

Tolerance stack-up testing revealed that the system remains functional even with slight variations in component tolerances. The results showed that small manufacturing deviations in the alignment of the visible laser mirror, long pass filter, and other optical components did not significantly affect the overall performance. The system successfully maintained its beam merging and steering capabilities, even with minor misalignments, confirming that the ILU can be used in real-world applications where manufacturing tolerances may vary.

In the environmental tests, the ILU was exposed to temperature ranges from -10°C to 50°C and humidity levels up to 95% RH. The experimental results showed that the system’s alignment and beam steering mechanisms remained stable, with no significant drift in the direction of the merged beam. The system was able to maintain precise targeting even in dynamic environmental conditions, confirming its suitability for outdoor and field applications, where temperature and humidity can vary significantly.

The results of the beam divergence and focus quality tests demonstrated that the merged laser beam exhibited minimal divergence. The divergence was measured at 0.5 mrad, which is within the acceptable range for high-precision applications. The system was able to maintain a well-focused beam over a distance of 100 meters, confirming the high quality of the beam merging and focusing mechanisms.

The electronic control system (200) performed exceptionally well during real-time adjustments. The system was able to provide instantaneous corrections to the azimuth and elevation mirrors (170, 180) when the beam was misaligned or when environmental conditions caused shifts in the beam’s direction. The control system's feedback mechanism was responsive and accurate, ensuring that the system remained aligned with the target during dynamic operations, such as moving target simulations or changes in target location.

Finally, the laser safety compliance testing confirmed that the system met the Class 1 laser safety standards. The system's output power and wavelength were within the safe limits prescribed by regulatory bodies, ensuring that the ILU can be used in a variety of environments without posing a risk to users.

These experimental results validate the design and functionality of the Single Eye Integrated Laser Unit, demonstrating its ability to provide high-precision beam merging, reliable beam steering, and consistent performance under dynamic environmental conditions.
, C , Claims:5. CLAIMS
We claim:
1) An integrated laser unit (ILU) for merging visible and infrared (IR) laser beams into a single, coherent output beam for high-precision targeting, comprising:
a visible laser source (110) configured to emit a visible laser beam;
an infrared (IR) laser source (120) configured to emit a pulsed IR laser beam;
a visible laser mirror (130) positioned at a predetermined angle relative to the visible laser source (110), configured to reflect the visible laser beam toward a long pass filter (140);
a long pass filter (140) positioned in the optical path of the visible and IR laser beams, configured to transmit the IR beam while reflecting the visible laser beam, thereby merging the two beams into a single, unified output beam (150);
a compliant monolithic structure (160) supporting the visible laser mirror (130) and long pass filter (140), the structure (160) allowing fine adjustments in at least two degrees of freedom (DOF), ensuring precise alignment of the visible and IR laser beams with minimal divergence and optimal beam merging;
an azimuth steering mirror (170) positioned downstream of the merged beam (150), configured for horizontal adjustments of the output beam (150) within a predetermined range to direct the beam along a horizontal axis;
an elevation steering mirror (180) positioned downstream of the azimuth steering mirror (170), configured for vertical adjustments of the output beam (150) within a predetermined range to direct the beam along a vertical axis;
a multi-axis adjustable frame (190) supporting both the azimuth and elevation steering mirrors (170, 180), wherein the frame (190) provides independent and simultaneous adjustments to achieve precise alignment of the merged laser output (150), allowing for high-accuracy targeting over long distances;
wherein, the integrated laser unit (100) merges the visible and IR laser beams with minimal beam divergence, enabling precise and stable beam direction control, adaptable to operational conditions such as temperature, humidity, and movement, making it suitable for high-performance applications requiring accurate laser alignment and targeting.

2) The integrated laser unit (ILU) as claimed in claim 1, wherein the visible laser source (110) comprises a diode laser with a wavelength range between 450 nm and 650 nm, and the pulsed infrared (IR) laser source (120) comprises a diode laser with a wavelength range between 850 nm and 1,100 nm.

3) The integrated laser unit (ILU) as claimed in claim 1, wherein the long pass filter (140) is fabricated from a substrate selected from the group consisting of BK7 glass and fused silica, and wherein the multi-layer anti-reflective coating (160) of the long pass filter (140) comprises silicon dioxide (SiO₂), titanium dioxide (TiO₂), and aluminium oxide (Al₂O₃) for enhanced spectral performance.

4) The integrated laser unit (ILU) as claimed in claim 1, wherein the azimuth steering mirror (170) is configured to elevate horizontal adjustments of the output beam (150) within a range of ±15 degrees from a neutral position, and the elevation steering mirror (180) is capable of vertical adjustments of the output beam (150) within a range of ±10 degrees from a neutral position.

5) The integrated laser unit (ILU) as claimed in claim 1, wherein the multi-axis adjustable frame (190) comprises a mechanism with precision adjustment screws (201) allowing angular adjustments of less than 0.1 degrees per rotation.

6) The integrated laser unit (ILU) as claimed in claim 1, wherein the system comprises an electronic control system (220) that provides real-time feedback on the orientations of the azimuth and elevation mirrors (170, 180), enabling automated adjustments based on operational parameters or user input.

7) The integrated laser unit (ILU) as claimed in claim 1, wherein the long pass filter (140) is designed to reflect light at approximately 625 nm wavelength while transmitting light at approximately 930 nm wavelength, enhancing the efficiency of the beam merging process.

8) The integrated laser unit (ILU) as claimed in claim 1, wherein the compliant monolithic structure (160) is made from a material selected from the group consisting of aluminum, titanium, and stainless steel to provide structural stability while allowing fine adjustments.

9) The integrated laser unit (ILU) as claimed in claim 1, wherein the long pass filter (140) comprises a multi-layer coating applied using Ion Beam Sputtering (IBS) or Electron Beam Evaporation (EBE), wherein the coating is optimized for high optical performance at the specified wavelengths.

10) A method of manufacturing the integrated laser unit (ILU) as claimed in claim 1, the method comprising:
providing a visible laser source (110) and a pulsed infrared (IR) laser source (120);
configuring a visible laser mirror (130) at a predetermined angle relative to the visible laser source (110) to reflect the visible laser beam toward the long pass filter (140);
selecting a substrate material for the long pass filter (140) from the group consisting of BK7 glass and fused silica;
depositing a multi-layer anti-reflective coating (160) on the substrate of the long pass filter (140), wherein the coating comprises silicon dioxide (SiO₂), titanium dioxide (TiO₂), and aluminium oxide (Al₂O₃) using Ion Beam Sputtering (IBS) or Electron Beam Evaporation (EBE);
mounting the visible laser mirror (130) and long pass filter (140) on a compliant monolithic structure (160) that allows adjustments in at least two degrees of freedom (DOF) to ensure precise alignment of the visible and IR laser beams;
assembling an azimuth steering mirror (170) and an elevation steering mirror (180) downstream of the merged beam (150), allowing for horizontal and vertical adjustments of the output beam (150), respectively;
placing the azimuth and elevation mirrors (170, 180) onto a multi-axis adjustable frame (190) that enables independent and simultaneous adjustments for precise alignment and beam direction control;
calibrating the system to ensure minimal beam divergence and high-accuracy targeting performance over extended distances.

6. DATE AND SIGNATURE
Dated this 28th November 2024
Signature

(Mr. Srinivas Maddipati)
IN/PA 3124
Agent for Applicant