Patent Description:
Lasers are commonly used in materials processing, including cutting, welding, brazing, surface treatment and other applications. Laser systems are offered in many different configurations, or are custom designed, to meet the needs of customers, not only in terms of properties/intensities of light, but also in terms of feeding fiber design and length. Damage to a feeding fiber can be quite costly from both a cost of replacement and a cost of system downtime point of view, as the feeding fiber is generally not easily replaceable. Therefore, there is a need for a laser optical fiber tray that can protect the feeding fiber when not in use and can be adjustable to the length of exposed feeding fiber needed at a given time.

<CIT> discloses a conductor spool with a frame having an entry slot and an exit slot. <CIT> discloses a terminal enclosure for optical fibers including an extractable fiber organizer tray. <CIT> discloses a fiber management tray including a fiber transition opening. <CIT> discloses an enclosure assembly for protecting and housing fiber optic cable within fiber optic equipment. The enclosure assembly includes a housing having an open end for detachably receiving a tray.

According to a first aspect of the present invention there is provided a laser system as claimed in claim <NUM>.

According to a second aspect of the present invention there is provided a laser system as claimed in claim <NUM>.

The material described herein is illustrated by way of example and not by way of limitation in the accompanying figures. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements. In the figures:.

One or more embodiments are described with reference to the enclosed figures. While specific configurations and arrangements are depicted and discussed in detail, it should be understood that this is done for illustrative purposes only. Persons skilled in the relevant art will recognize that other configurations and arrangements are possible without departing from the scope of the description. It will be apparent to those skilled in the relevant art that techniques and/or arrangements described herein may be employed in a variety of other systems and applications other than what is described in detail herein.

Reference is made in the following detailed description to the accompanying drawings, which form a part hereof and illustrate exemplary embodiments. Further, it is to be understood that other embodiments may be utilized and structural and/or logical changes may be made without departing from the scope of claimed subject matter. It should also be noted that directions and references, for example, up, down, top, bottom, and so on, may be used merely to facilitate the description of features in the drawings. Therefore, the following detailed description is not to be taken in a limiting sense and the scope of claimed subject matter is defined solely by the appended claims and their equivalents.

In the following description, numerous details are set forth. However, it will be apparent to one skilled in the art, that the present invention may be practiced without these specific details. In some instances, well-known methods and devices are shown in block diagram form, rather than in detail, to avoid obscuring the present invention. Reference throughout this specification to "an embodiment" or "one embodiment" means that a particular feature, structure, function, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. Thus, the appearances of the phrase "in an embodiment" or "in one embodiment" in various places throughout this specification are not necessarily referring to the same embodiment of the invention.

As used in the description of the invention and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.

The terms "coupled" and "connected," along with their derivatives, may be used herein to describe functional or structural relationships between components. Rather, in particular embodiments, "connected" may be used to indicate that two or more elements are in direct physical, optical, or electrical contact with each other. "Coupled" may be used to indicated that two or more elements are in either direct or indirect (with other intervening elements between them) physical or electrical contact with each other, and/or that the two or more elements co-operate or interact with each other (e.g., as in a cause an effect relationship).

The terms "over," "under," "between," and "on" as used herein refer to a relative position of one component or material with respect to other components or materials where such physical relationships are noteworthy.

As used throughout this description, and in the claims, a list of items joined by the term "at least one of" or "one or more of" can mean any combination of the listed terms. For example, the phrase "at least one of A, B or C" can mean A; B; C; A and B; A and C; B and C; or A, B and C.

A laser system generally includes a rack with a plurality of laser modules mounted in the rack to drive light through an optical fiber exiting the system. The exiting fiber, or feeding fiber, can extend dozens of feet in length for inclusion in large material processing tools, for example. Conventionally, the feeding fiber is exposed, and subject to environmental hazards, when not in use. Shipping and relocating of a laser system can be particularly high risk events for the feeding fiber. In some embodiments described hereinafter, the optical fiber tray may include an enclosure to safely coil and store the feeding fiber. In some embodiments described hereinafter, the optical fiber tray may include coil guides that define a minimum diameter for a loop of the feeding fiber to be contained within the enclosure. Also, in some embodiments, one or more external modules are included between the rack and the optical fiber tray, as described in more detail hereinafter, to further customize properties of the laser beam and/or to provide a connection point where the feeding fiber can be swapped out if necessary.

Some benefits of the laser optical fiber tray and external module described hereinafter include, but are not limited to, enhanced reusability, durability, serviceability, and expandability. For example, the same laser system rack with rack-mounted laser modules can become more standardized with customizations added (after initial delivery and use in some cases) to an external module or optical fiber tray to create a specific laser system to meet the customer needs potentially in terms of modulation frequency, rise/fall times, beam quality, wavelength, fiber properties and fiber length. This can lead to reduced design time by allowing the same laser system rack to be reused among various product lines without have to increase rack height to accommodate additional modules. Additionally, not only would the feeding fiber be better protected from damage with the use of the optical fiber tray, the use of a coupler in the optical fiber tray or external module can enable the quick replacement of the feeding fiber in the event of damage to the original feeding fiber or in the event of system modification requiring a change to a different feeding fiber.

A block diagram of an example laser system that may benefit from incorporating embodiments of the present invention is depicted in <FIG>. As shown, laser system <NUM> includes power distribution module <NUM>, pump modules <NUM>, combiner/gain module <NUM>, exit fiber <NUM>, AC input <NUM>, AC output <NUM>, optical fibers <NUM>, and circuit branches <NUM>. Different and/or additional modules may be included in laser system <NUM> without deviated from the scope of the present invention. For example, separate or multiple combiner/gain modules may be used. Also, any number of pump modules <NUM> may be present. In one embodiment, six pump modules are included in laser system <NUM>. Laser system <NUM> may be a direct diode laser system, a fiber laser system, or any other type of laser system that may benefit from incorporating embodiments of the present invention.

Power distribution module <NUM> may distribute power in the form of AC Voltage received as AC input <NUM> to pump modules <NUM> and combiner/gain module <NUM> through AC output <NUM>. Circuit branches <NUM> within power distribution module <NUM> may include circuit components to branch AC input <NUM> into multiple independent AC outputs <NUM>. In some embodiments, AC input <NUM> is <NUM> phase AC which is distributed through circuit branches <NUM> as single phase AC outputs <NUM>. In some embodiments, circuit branches <NUM> may also convert AC Voltage to DC Voltage for use with additional components (not shown) in laser system <NUM>.

Circuit branches <NUM> may include a circuit breaker, a contactor, a line filter, and/or a terminal block for each AC output <NUM>. The components of circuit branches <NUM> may be chosen based on the voltage and current requirements of modules <NUM> and <NUM>. In one embodiment, each of AC outputs <NUM> provide 480VAC, though the present invention is not so limited. In some embodiments, AC output <NUM> may vary by module. For example, AC output <NUM> may deliver a different voltage or a same voltage at a different amperage to pump module <NUM> than AC output <NUM> delivers to combiner/gain module <NUM>.

Circuit branches <NUM> may be designed to protect modules coupled with AC outputs <NUM> from damage caused by overcurrent or overload or short circuit. Circuit branches <NUM> may interrupt current flow through one or more of AC outputs <NUM> after protective relays detect a fault. Circuit branches <NUM> may be manually or automatically resettable after a fault. Additionally, circuit branches <NUM> may attenuate conducted electromagnetic interference (EMI) from AC input <NUM> to AC outputs <NUM>. Circuit branches <NUM> may be controlled by software or firmware either internal to or external from laser system <NUM>.

One or more pump modules <NUM> may be included in laser system <NUM> to drive light through optical fibers <NUM>. In some embodiments, each of pump module <NUM> may include a DC power supply to convert AC output <NUM> into direct current that powers laser diodes. In some embodiments, each of pump module <NUM> includes one or more liquid-cooled coldplate(s) for heat dissipation.

Combiner/gain module <NUM> may include coiled fiber to increase light output and may combine optical fibers <NUM> into a single exit fiber <NUM> that exits laser system <NUM>. Additional modules (not shown) may be included in laser system <NUM> to control and/or condition the light driven through exit fiber <NUM> when laser system <NUM> is operating.

Exit fiber <NUM> may have any diameter and length. In one embodiment, exit fiber <NUM> is up to <NUM> feet in length. Exit fiber <NUM> may be a single length of fiber or may be multiple lengths of fiber coupled together. In some embodiments, a first shorter exit fiber <NUM> is coupled with a coupler or other optical product which is coupled with a second longer fiber. Additionally, in some embodiments exit fiber <NUM> may be single clad while in some embodiments exit fiber <NUM> may be double clad.

Turning now to <FIG>, a 3D drawing of an example laser system, in accordance with some embodiments, is shown. Laser system <NUM> includes rack <NUM>, power distribution module <NUM>, exit fiber <NUM>, laser modules <NUM>, and rack top panel <NUM>. Rack <NUM> may provide the structure and mounting points for supporting and containing the various modules of laser system <NUM>. Rack <NUM> may be of standard or non-standard dimensions. Rack <NUM> may include additional elements not shown or may be implemented without all elements shown (for example wheels). Rack top panel <NUM> may include openings and features, as described in more detail hereinafter, to enable aspects of a laser optical fiber tray.

In some embodiments, rack <NUM> includes a <NUM>-inch standardized rack frame for mounting laser modules <NUM>. In some embodiments, rack <NUM> includes a <NUM>-in standardized rack frame. In other embodiments, different rack widths may be used. In some embodiments the height of rack <NUM> is standardized in multiples of <NUM> inches or one rack unit or U. In one embodiment, rack <NUM> is <NUM> U tall. In other embodiments different rack heights may be used. In some embodiments, rack <NUM> is a four vertical post rack that allows for mounting rails to support laser modules <NUM> at the front and rear. In other embodiments, rack <NUM> is a two vertical post rack. In some embodiments, rack <NUM> is open in construction, while in other embodiments rack <NUM> is enclosed, for example by doors, side panels and a top.

Rack <NUM> may have provisions for airflow and cooling of laser modules <NUM>. In some embodiments, front and/or side air intakes are included as well as rear exhaust. Forced air fan cooling may or may not be included. In some embodiments, liquid cooling is provided to each of laser modules <NUM> in the form of cold plates supported by conduit, pumps, liquid inlets, liquid outlets, and drains.

Power distribution module <NUM> and laser modules <NUM> (which may include pump module <NUM> and combiner/gain module <NUM>) are mounted within rack <NUM>. Power distribution module <NUM> may have both AC and DC outputs.

Exit fiber <NUM> may exit laser system <NUM> through an opening in rack top panel <NUM>. Exit fiber <NUM> may include many feet of optical fiber to interface with external tools (not shown). Conventionally, laser system <NUM> may be shipped or stored with exit fiber <NUM> laying on rack top panel <NUM> exposed to the environment without protection or containment. In some cases, a cardboard box may be used conventionally to provide a measure of packaging.

<FIG> is a 3D drawing of an example laser system including an optical fiber tray, in accordance with some embodiments. As shown, laser system <NUM> includes rack <NUM>, optical fiber tray <NUM>, depth <NUM> and width <NUM>. Optical fiber tray <NUM> may be seated on, and interface with rack top panel <NUM>. Some of the ways in which optical fiber tray <NUM> and rack <NUM> may interface are described in more detail herein, for example with reference to <FIG>, <FIG> and <FIG>.

In some embodiments, optical fiber tray <NUM> is made of steel or other metals. In some embodiments, the enclosure of optical fiber tray <NUM> is made of the same material and thickness as rack <NUM>. One skilled in the art would appreciate that based at least on the materials used, optical fiber tray <NUM> can provide a relatively strong and durable enclosure to protect the feeding fiber from many common environmental hazards associated with shipping and storage.

As shown, optical fiber tray <NUM> and rack <NUM> may be substantially equal in both depth <NUM> and width <NUM>. One skilled in the art would appreciate that by being substantially equal in two dimensions, not only may manufacturers be able to offer an aesthetically pleasing laser system <NUM>, but they would also be able to maximize the volume within optical fiber tray <NUM> to hold feeding fiber, and potentially other components, while limiting the height of optical fiber tray <NUM>. However, in some embodiments, optical fiber tray <NUM> may only be substantially equal with rack <NUM> in one of depth <NUM> or width <NUM>, but not both dimensions. In other embodiments, optical fiber tray <NUM> is not substantially equal with rack <NUM> in either depth <NUM> or width <NUM>.

<FIG> is an overhead drawing showing the interior of an example optical fiber tray, in accordance with some embodiments. As shown, the interior of optical fiber tray <NUM> may include feeding fiber <NUM>, side fiber opening <NUM>, split bushing <NUM>, inner coil guides <NUM>, outer coil guides <NUM>, minimum coil diameter <NUM>, ties <NUM>, liquid supply port <NUM>, liquid return port <NUM>, liquid supply conduit <NUM>, and liquid return conduit <NUM>. Optical fiber tray <NUM> would include a top panel in most embodiments that would need to be removed to access the interior of optical fiber tray <NUM>, however it is not shown in this figure.

Side fiber opening <NUM> in optical fiber tray <NUM> allows passage of feeding fiber <NUM> out of the enclosure. In some embodiments the size of side fiber opening <NUM> allows for passage of feeding fiber <NUM> as well as attachments to an end of feeding fiber <NUM>. In some embodiments, when laser system <NUM> is not in use, the entire length of feeding fiber <NUM> can be contained within optical fiber tray <NUM>. In other embodiments, when laser system <NUM> is not in use, a portion of feeding fiber <NUM> or attachments thereon may remain within side fiber opening <NUM>. In some embodiments, to adjust the length of feeding fiber <NUM> that extends out of optical fiber tray <NUM>, split bushing <NUM> must first be removed from side fiber opening <NUM>. Feeding fiber <NUM> may then be able to be uncoiled and passed through side fiber opening <NUM> to the extent needed, for example for using laser system <NUM> with a material processing tool. When the desired length of feeding fiber <NUM> is outside of optical fiber tray <NUM>, split bushing <NUM> may then be disposed within side fiber opening <NUM> to grip feeding fiber <NUM> and resist further passage of feeding fiber <NUM> in or out of side fiber opening <NUM>.

In some embodiments, split bushing <NUM>, which may be made of plastic or rubber and may have smooth surfaces to contact feeding fiber <NUM>, may also protect feeding fiber <NUM> from contacting any edges of optical fiber tray <NUM> at side fiber opening <NUM>. One skilled in the art would appreciate that by exposing only as much of the length of feeding fiber <NUM> as is needed for use at a given time to potential environmental hazards outside of optical fiber tray <NUM>, there is less risk to any excess of feeding fiber <NUM> that isn't being used. Additionally, the length of feeding fiber <NUM> being used at a given time may be able to be more easily managed and kept under control without bends or loops.

Inner guide posts <NUM> and outer guide posts <NUM> may be affixed to the bottom of optical fiber tray <NUM>. Inner guide posts <NUM> may be spaced apart by a distance that defines minimum coil diameter <NUM> for a loop of feeding fiber <NUM> to be contained within optical fiber tray <NUM>. In some embodiments, minimum coil diameter <NUM> is chosen to be at least a minimum bend radius of feeding fiber <NUM>. In some embodiments, minimum coil diameter <NUM> is in the range of about <NUM> to <NUM> inches. In some embodiments, each of outer guide posts <NUM> are spaced apart from the nearest inner guide post <NUM> by a distance sufficient to contain a plurality of concentric loops of feeding fiber <NUM>. In some embodiments, the height of and the distance between the inner guide posts <NUM> and outer guide posts <NUM> allow for <NUM> meters of feeding fiber <NUM> to be coiled in optical fiber tray <NUM>. While shown as including two pairs of inner guide posts <NUM> and outer guide posts <NUM>, in some embodiments only one pair or three or more pairs may be used. In some embodiments, only inner guide posts <NUM> are used. Also, while the pairs of inner and outer posts are shown as positioned at <NUM> and <NUM> o'clock, in some embodiments they are at different relative positions, for example at <NUM> and <NUM> o'clock. In some embodiments, a straight line from the inlet of feeding fiber <NUM> into optical fiber tray <NUM> to side fiber opening <NUM> bifurcates the distance between one inner and outer guide post pair (depicted in <FIG> as line <NUM> bifurcating the distance between the guide post pair at the <NUM> o'clock position).

Ties <NUM> may be included in optical fiber tray <NUM> to fasten together a plurality of loops of feeding fiber <NUM>. Ties <NUM> may represent reusable zip ties. In some embodiments, ties <NUM> may represent hook and loop ties. While shown as including <NUM> Ties <NUM>, any number of ties may be used. Also, while Ties <NUM> are shown as positioned at <NUM>, <NUM> and <NUM> o'clock, in some embodiments they are at different relative positions, for example at <NUM>, <NUM> and <NUM> o'clock.

Liquid supply port <NUM> and liquid return port <NUM> may be included on the same side of optical fiber tray <NUM> as, and may be within a few inches of, side fiber opening <NUM>. When laser system <NUM> is operating, high amounts of heat may be generated at the end of feeding fiber <NUM>. As such, liquid supply port <NUM> may interface with external conduit to supply liquid to (and liquid return port <NUM> may interface with external conduit to return liquid from) a liquid thermal solution, such as a coldplate, to dissipate heat from the end of feeding fiber <NUM> through a liquid-cooling circuit. Optical fiber tray <NUM> may include liquid supply conduit <NUM> and liquid return conduit <NUM> to extend the liquid-cooling circuit to and from rack <NUM>.

<FIG> is a drawing of a bottom of an example optical fiber tray, in accordance with some embodiments. As shown, the bottom of fiber tray <NUM> includes bottom fiber opening <NUM>, and may include electrical interface <NUM>, liquid supply port <NUM>, liquid return port <NUM>, drain port <NUM>, and fastener holes <NUM>. In some embodiments, <FIG> also represents a bottom of an external module (minus feeding fiber <NUM>, liquid supply port <NUM>, and liquid return port <NUM>).

Bottom fiber opening <NUM> accepts a feeding (or intermediary) fiber exiting from a top of laser system rack <NUM>. Bottom fiber opening <NUM> may be rectangular in shape with longer sides oriented in parallel with longer sides of optical fiber tray <NUM>. Bottom fiber opening <NUM> may include housing that provides a fiber inlet to accept a fiber in a substantially vertical orientation and bend it to a substantially horizontal orientation.

Electrical interface <NUM> may be part of an electrical circuit to provide power from power distribution module <NUM> in rack <NUM> to elements of optical fiber tray <NUM> by interfacing with electrical contacts on rack top panel <NUM>. While shown as being round, electrical interface <NUM> may be rectangular or another shape. Electrical interface <NUM> may be positioned equidistant from the longer sides of optical fiber tray <NUM>.

Liquid supply port <NUM> and liquid return port <NUM> may be coupled with liquid supply conduit <NUM> and liquid return conduit <NUM>, respectively, and may interface with corresponding ports in rack top panel <NUM>. Liquide supply port <NUM> and liquid return port <NUM> may be oriented in parallel with, and within one diameter distance from, a longer side of optical fiber tray <NUM>.

Drain port <NUM> may allow any liquid that may leak from the liquid-cooling circuit within optical fiber tray <NUM> to drain down into a corresponding opening in rack <NUM>. Drain port <NUM> may be positioned along the same side of optical fiber tray <NUM> as liquid supply port <NUM> and liquid return port <NUM>.

Fastener holes <NUM> may allow optical fiber tray <NUM> to be bolted to corresponding fastener holes on rack top panel <NUM>. Fastener holes <NUM> may be present in each corner of optical fiber tray <NUM> as well along midway of the longer sides of optical fiber tray <NUM>.

<FIG> is a drawing of a top of an example laser rack, in accordance with some embodiments. As shown, rack top panel <NUM> may include fiber opening <NUM>, electrical interface <NUM>, liquid supply <NUM>, liquid return <NUM>, drain <NUM>, and fastener holes <NUM>. In some embodiments, <FIG> also represents a top of an external module (minus the wheels).

Fiber opening <NUM> may allow a fiber to exit rack <NUM> and transition through bottom fiber opening <NUM>. Fiber opening <NUM> may be rectangular in shape with its longer sides representing the approximate distance from fiber opening <NUM> to a side of rack <NUM> orthogonal to the longer sides.

Electrical interface <NUM> may be oriented and configured to electrically couple with electrical interface <NUM> when optical fiber tray <NUM> is placed on rack <NUM>. Electrical interface <NUM> include one or more pairs of power and ground connections.

Liquid supply <NUM> and liquid return <NUM> may interface with liquid supply port <NUM> and liquid return port <NUM>, respectively, to exchange water between rack <NUM> and optical fiber tray <NUM> as part of a liquid-cooling circuit. Drain <NUM> may interface with drain port <NUM> when optical fiber tray <NUM> is installed on rack <NUM> to collect any liquid that leaks in optical fiber tray <NUM>.

Fastener holes <NUM> may form a bolt pattern that aligns with the bolt pattern in the bottom of optical fiber tray <NUM> so that optical fiber tray <NUM> can be securely mounted to rack <NUM> with screws. Fastener holes <NUM> may be positioned in imaginary lines parallel to shorter sides of rack <NUM>, and <NUM> fastener holes <NUM> may be present along such a midway line.

<FIG> is a diagram of an example laser system with an optical fiber tray, in accordance with some embodiments. As shown, rack <NUM> may include fiber opening <NUM>, fiber housing <NUM>, electrical interface <NUM>, power distribution module <NUM>, drain <NUM>, liquid receptacle <NUM>, and leak detector <NUM>, while optical fiber tray <NUM> includes removable top <NUM>, bottom fiber opening <NUM>, inner coil guides <NUM>, and outer coil guides <NUM>, and may include ties <NUM>, split bushing <NUM>, electrical interface <NUM>, light tower <NUM>, pitched surface <NUM> and drain port <NUM>.

Optical fiber tray <NUM> includes removable top <NUM> to allow access to the interior of the enclosure. Removable top <NUM> may be hinged or unhinged. In some embodiments, removable top <NUM> rests on and can be bolted to standoffs (not shown) affixed to the interior bottom of optical fiber tray <NUM>. In some embodiments, inner coil guides <NUM> and outer coil guides <NUM> extend high enough to support removable top <NUM> and also function as standoffs.

Pitched surface <NUM> may be included in optical fiber tray <NUM> to direct any liquid that may leak (for example from liquid supply conduit <NUM> or liquid return conduit <NUM>) toward drain port <NUM>. Pitched surface <NUM> may extend <NUM> degrees around drain port <NUM> similar to a bathtub. Pitch surface <NUM> may have a constant or variable pitch toward drain port <NUM>. When optical fiber tray <NUM> is installed on rack <NUM>, drain port <NUM> would interface with drain <NUM> to transfer any liquid present through drain conduit to liquid receptacle <NUM> at or near the bottom of rack <NUM>. As liquid accumulates in liquid receptacle <NUM>, it may be sensed by leak detector <NUM>. Leak detector <NUM> may electrically and/or communicatively coupled with power distribution module <NUM> to respond to a detected leak. In some embodiments, a detected leak could cause power distribution module <NUM> to turn off power to laser modules in rack <NUM>. In some embodiments, a detected leak could cause a warning light to be displayed on light tower <NUM>.

Light tower <NUM> may be present on top of optical fiber tray <NUM> to communicate status information about laser system <NUM>. Light tower <NUM> may include any number and color of lights, perhaps LED lights. In some embodiments, light tower <NUM> receives DC voltage to operate from power distribution module <NUM> through electrical couplings with electrical interfaces <NUM> and <NUM>.

Fiber housing <NUM> may protrude from the top of rack <NUM> to guide exit fiber <NUM> into optical fiber tray <NUM>. Fiber housing <NUM> may include a cross-support to allow exit fiber <NUM> to gradually bend from substantially vertical to substantially horizontal. In some embodiments, fiber housing <NUM> is instead recessed within optical fiber tray <NUM>.

<FIG> is a diagram of an example laser system with an external module, in accordance with some embodiments. As shown, laser system <NUM> includes external module <NUM> which includes coupler <NUM>, bottom opening <NUM>, and top opening <NUM>, and which may also include exit fiber <NUM>, feeding fiber <NUM>, fastener holes <NUM>, electrical interfaces <NUM>, drain openings <NUM>, top liquid connections <NUM> and bottom liquid connections <NUM>. While shown as including one external module <NUM>, laser system <NUM> may include two or more external modules <NUM> of similar or varying complexity. External modules <NUM> can be inserted in between the rack <NUM> and optical fiber tray <NUM> which do various things to the beam characteristics, with optical fiber tray <NUM> being added to laser system <NUM> at the end of the optical path. A common interface, as described in reference to <FIG>, at the top of rack <NUM> mates with either optical fiber tray <NUM>, or any other external module <NUM>. The top of external modules <NUM> would have the same interface as rack top panel <NUM>, and optical fiber tray <NUM> mated to the top of them. This approach enables a "plug and play" implementation where an unlimited number of modules that can modify the optical properties of the laser and be placed in the optical path. At the end of the path optical fiber tray <NUM> manages feeding fiber <NUM> for customer use.

Coupler <NUM> is included in external module <NUM> to couple exit fiber <NUM> received from rack <NUM> through bottom opening <NUM> with feeding fiber <NUM> passed to optical fiber tray <NUM> through top opening <NUM>. Coupler <NUM> may represent any one or more optical couplers, such as including, but not limited to, a variable beam properties product (vBPP), a fiber-fiber coupler (FFC), or a fiber-fiber switch (FFS). In some embodiments, coupler <NUM> may be included within optical fiber tray <NUM>. Coupler may be designed to modify properties of light driven through feeding fiber <NUM> or may pass light through unaltered.

Fastener holes <NUM> in external module <NUM> may match with the bolt patterns of fastener holes <NUM> of optical fiber tray <NUM> and fastener holes <NUM> of rack <NUM>, such that external module <NUM> can be securely mounted in laser system <NUM>. The enclosure of external module <NUM> may include a removable top to allow access to the interior of the enclosure, for example to couple fibers and install screws.

External module <NUM> may also include a bathtub-like pitch bottom to direct liquid to the bottom of drain openings <NUM>, which interface with and couple drain port <NUM> with drain <NUM>. Top liquid connections <NUM> may interface with and couple liquid supply port <NUM> and liquid return port <NUM> through conduit to liquid supply <NUM> and liquid return <NUM>, respectively, which may interface and couple with bottom liquid connections <NUM>. While shown as bridging the liquid-cooling circuit between rack <NUM> and optical fiber tray <NUM>, in some embodiments, external module <NUM> may include branches off of the liquid-cooling circuit, for example directed to a coldplate at coupler <NUM>.

A flowchart of an example method of assembling a laser system, in accordance with some embodiments, is shown in <FIG>. The method begins with installing (<NUM>) external module <NUM>, if it is to be used, on rack <NUM>, in some embodiments. A top of external module <NUM> may be removed to install screws or bolts through fastener holes <NUM> into fastener holes <NUM>.

The method continues with connecting (<NUM>) exit fiber <NUM>, which may be pulled up through fiber opening <NUM>, and feeding fiber <NUM> to coupler <NUM>, in some embodiments. After the fibers are connecting a top, which may have a bolt pattern matching that of fastener holes <NUM> of rack top panel <NUM>, may be replaced on external module <NUM>. Additional external modules <NUM> may be installed in a similar manner.

Next, optical fiber tray <NUM> is installed (<NUM>) on external module <NUM> (if present as in <FIG>) or on rack <NUM> (if external module <NUM> is not included). Removable top <NUM> may be removed to access the interior of optical fiber rack <NUM>. Screws or bolts tightened through fastener holes <NUM> to secure optical fiber rack <NUM> in place. Feeding fiber <NUM> may be pulled up through bottom fiber opening <NUM>.

The method concludes with coiling (<NUM>) feeding fiber <NUM> within optical fiber tray <NUM> between inner coil guides <NUM> and outer coil guides <NUM>, in some embodiments. The coils of feeding fiber <NUM> may be held together by one or more of ties <NUM>. Removable top <NUM> may then be replaced and secured.

<FIG> is a flowchart of an example method of readying a laser system for use, in accordance with some embodiments. The method begins with accessing (<NUM>) the interior of optical fiber tray <NUM> by removing removable top <NUM>, in some embodiments.

The method continues with uncoiling (<NUM>) and moving feeding fiber <NUM> out through side fiber opening <NUM>, in some embodiments. In some embodiments, split bushing <NUM> would need to be removed from side fiber opening <NUM> to allow access for feeding fiber <NUM>. A number of coils of feeding fiber <NUM> may be lifted up and over inner coil guides <NUM> and outer coil guides <NUM> until the needed length of feeding fiber <NUM> has been moved out of optical fiber tray <NUM>.

Next, split bushing <NUM> may be secured (<NUM>) within side fiber opening <NUM>, in some embodiments. Split bushing <NUM> may include screw-on or snap-on pieces to grip feeding fiber <NUM> and hinder movement of feeding fiber <NUM> into or out of side fiber opening <NUM>.

The method concludes with connecting (<NUM>) conduit to liquid supply port <NUM> and liquid return port <NUM>, in some embodiments. In some embodiments, main liquid supply and return conduits would need to be connected to ports in rack <NUM> that interface with liquid supply port <NUM> and liquid return port <NUM> in optical fiber tray <NUM>.

Claim 1:
A laser system, comprising:
a laser system rack (<NUM>), comprising:
a plurality of laser modules (<NUM>, <NUM>) mounted in the rack (<NUM>) to drive light through an optical fiber (<NUM>) exiting the system;
a power distribution module (<NUM>) disposed within the rack (<NUM>) to distribute input electricity to the laser modules (<NUM>, <NUM>);
a top panel (<NUM>); and
an optical fiber tray (<NUM>) mounted on the top panel (<NUM>) of the laser system rack (<NUM>), the tray comprising:
an enclosure mounted atop the laser system rack, the enclosure with a removable top panel (<NUM>) to allow access to an interior of the enclosure, wherein the enclosure has a first opening (<NUM>) in the bottom of the enclosure to face the laser system rack (<NUM>), said opening (<NUM>) arranged to accept a feeding fiber (<NUM>) exiting from the top panel (<NUM>) of the laser system rack (<NUM>), and a second opening (<NUM>) in a side of the enclosure to allow passage of the feeding fiber (<NUM>) out of the enclosure; and
two or more coil guides (<NUM>) affixed within the interior of the enclosure, the coil guides spaced apart by a distance that defines an inner diameter (<NUM>) for a loop of the feeding fiber (<NUM>) to be contained within the interior of the enclosure, the inner diameter (<NUM>) substantially parallel to the bottom of the enclosure.