Patent Description:
HEL systems use multiple laser fibers and combine them for high power. One previous concept provides a four-fiber mount that allows alignment of the fibers to each other, but has no adjustability for the array, which means the array cannot be swapped out without the system being realigned to it. It also does not have final locking features to ensure the fibers do not move after adjustment and would therefore, not be stable in an operational environment. Based on this arrangement, the scaling to a larger number of fibers would create an unstable design.

Therefore, there is a need for a "field-able" fiber mount that holds multiple fiber endcaps, allows them to be individually adjusted relative to each other, and then be placed into the laser system and be aligned as an array to the existing system.

<CIT> discloses a multi-fiber fiber optic connector assembly providing articulated force application, including: a ferrule holder including an x-pivot component and a y-pivot component, wherein the x-pivot component of the ferrule holder is operable for providing relative rotational movement about the x-axis of the multi-fiber fiber optic connector assembly and the y-pivot component of the ferrule holder is operable for providing relative rotational movement about the x-axis of the multi-fiber fiber optic connector assembly. <CIT> describes a multi-fiber fiber optic ferrule comprising a ferrule body, at least one optically functional optical fiber received within at least one optical fiber bore defined by the ferrule body, and at least one optically non-functional guard fiber received within at least one guard fiber bore defined by the ferrule body. <CIT> discloses a cable assembly having a universal joint so as to rotate the connector thereof through X and Y directions. Upper and lower housings of the connector is provided with traverse bearings. A front edge of a front rotating arm is provided with assembled traverse shafts. A rear portion of the front rotating arm is provided with a slot in which axial holes are defined. <CIT> describes a fiber optic wiring guide wherein mechanical strength is increased and line arrangement ability is improved, with a simple and low-cost structure including a plurality of plate-like bases formed in the same shape that are connected and formed in bendable manner, and a fiber optic is arranged and streamed in a guide part provided upright on each of the bases. A shaft of one base is pivoted by a pivot part of the other base, being continuously connected together to form the fiber optic wiring guide.

According to various embodiments, an optical fiber holder is provided according to claim <NUM>.

In some embodiments, the plurality of protrusions are connected to the second holder through a plurality of adjusters. In other embodiments, the plurality of protrusions comprises of first, second and third protrusions.

In some embodiments, each of the plurality of holes includes an adhesive material to hold the optical fibers in their respective holes after alignment. In some embodiments, the plurality of optical fibers includes a respective plurality of end caps. In some embodiments, each of the plurality of end caps is located in a respective one of the plurality of holes. In some embodiments, the plurality of end caps are made of fused silica.

In some embodiments, the second holder can include a first beam having a first end and a second end, and a first curved piece being attached to the first end and the second end of the first beam. Further, the second holder can include a second curved piece being attached to the first beam. The first curved piece and the second curved piece being located on opposite sides of the first beam. Further, the second holder can include a second beam being attached to the first curved piece and the first beam, the second beam being perpendicular to the first beam.

In some embodiments, the first portion of the third holder includes a planar top piece and a planar bottom piece having first, second, third, and fourth corners, a length between the first and second corners being greater than the length between the first and the third corners and being equal to the length between the third and fourth corners. The planar bottom piece can be attached to the planar top piece and can define the plurality of holes therethorugh. The plurality of holes can be located on a plane perpendicular to a virtual Y-axis defined from the first upper surface to the first lower surface. The second and third protrusions are connected to the bottom piece at the first corner and the second corner, respectively.

In some embodiments, the third holder includes a second portion. The second portion can include a third beam having a first end and a second end, the first end being attached to the first portion of the third holder and the second end being attached to a first hollow rectangular piece and a second hollow rectangular piece. The first and second hollow rectangular pieces can be located at opposite sides of the third beam and can be in a same plane as the third beam. The third beam can have the first protrusion at the second end being operably connected to the second holder.

In some embodiments, the first holder is configured to move along a virtual X-axis and a Z-axis defined in a plane parallel to the first lower surface of the first holder.

In some embodiments, the third holder can move in the virtual Y-axis at times the first, second, and third protrusions move along the virtual Y-axis. In other embodiments, the third holder can rotate about the virtual X-axis at times the first protrusion moves along the virtual Y-axis. In some embodiments, can rotate about the virtual Z-axis at times the second and third protrusions move along the virtual Y-axis.

A method of aligning a plurality of optical fibers is provided according to claim <NUM>.

In some embodiments, attaching the third holder to the second holder is through a plurality of protrusions. The plurality of protrusions can include a first, second and third protrusions each having a linear adjuster.

Various aspects of at least one embodiment of the present disclosure are discussed below with reference to the accompanying figures. It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn accurately or to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. The figures are provided for the purposes of illustration and explanation and are not intended as a definition of the limits of the invention.

In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. It will be understood by those of ordinary skill in the art that these embodiments may be practiced without some of these specific details. In other instances, well-known methods, procedures, components and structures may not have been described in detail so as not to obscure the described embodiments.

Prior to describing at least one embodiment in detail, it is to be understood that the claims are not limited in their application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description only and should not be regarded as limiting.

The present disclosure provides an optical fiber device that can hold multiple fibers, e.g., two fibers to hundreds of fibers, and allows them to be individually adjusted relative to each other, and then be placed into a laser system and be aligned as an array to the existing system. The present disclosure allows the individual fibers to be adjusted in <NUM> degrees of freedom relative to each other. In addition, the present disclosure provide a device in which the entire array of fibers can be adjusted in <NUM> degrees of freedom, which allows the user to align an existing optical system. The alignment of fibers is performed by integrated features and external tooling. After alignment, using bond injection, the fibers will be locked in their space.

More specifically, the present disclosure provides a device to adjust multiple fibers individually relative to each other and is scalable for any quantity and any size of fibers.

<FIG> illustrates an isometric view of an optical system <NUM>, according to certain embodiment. <FIG> illustrates a top view of the optical system <NUM>, according to certain embodiment. <FIG> illustrate that the optical system <NUM> includes an optical fiber holder <NUM> in contact with a working station <NUM> for holding a plurality of optical fibers <NUM>. The optical fiber holder <NUM> can be mounted or attached to the working station <NUM>. In some embodiments, the optical fiber holder <NUM> is threaded to the working station <NUM> through screws <NUM> (shown in <FIG>). Therefore, the optical fiber holder <NUM> stays on the pads <NUM> after threading screws <NUM> to the working station <NUM>. The system <NUM> also includes mirrors <NUM> to reflect optical light from the optical fibers <NUM> back and forth to finally combine the light into one beam on the grating <NUM>.

<FIG> illustrate various views of the optical fiber holder <NUM>, according to certain embodiments. <FIG> illustrate the optical fiber holder <NUM>, according to certain embodiments. <FIG> illustrates a top view of the optical holder <NUM>, according to certain embodiments. Referring to <FIG>, the optical holder <NUM> can have a first holder <NUM>. The first holder <NUM> can have any shape, e.g., rectangular, circular, triangular, or any shape. In some embodiments, the first holder <NUM> is a triangular plate. The first holder <NUM> has a first upper surface <NUM> and a first lower surface <NUM>. The first holder <NUM> is configured to be in contact with a working station <NUM> (shown in <FIG>) through the first lower surface <NUM>. The first holder <NUM> can be attached to the working station <NUM> through various means, e.g., screws <NUM>. In some embodiments, the optical fiber holder <NUM> is attached to the working station <NUM> with three screws <NUM>. The first holder <NUM> can move in virtual X and Z axes shown in <FIG>. The X and Z axes are in a plane parallel to the first lower surface <NUM> of the first holder <NUM>. The first holder <NUM> can be fixed to the working station <NUM> after alignment of optical fibers <NUM>. The first holder <NUM> can be made of any suitable material, e.g., plastics, metals, or alloys. The metals can be any metal, e.g., Aluminum, Stainless Steel, etc..

<FIG> illustrate a side view of the optical fiber holder <NUM> and a close up view of the screw <NUM>. After alignment of optical fibers <NUM>, the optical fiber holder <NUM> is threaded to the working station <NUM> through screws <NUM> and will be secured in its position to minimize or eliminate any movement of the optical fiber holder <NUM>. As <FIG> illustrates, the part of the screw <NUM> which is in the first holder <NUM> and the pad <NUM> is surrounded by a sleeve <NUM>. After alignment of the optical fibers <NUM>, the screws <NUM> are threaded to the working station <NUM> and an adhesive material <NUM> is injected through holes <NUM> to bond the screws <NUM> and the sleeves <NUM> to the first holder <NUM>. The excess amount of the adhesive (bond) can come out of the opening <NUM> to indicate that bonding is complete.

Referring to <FIG>, the optical fiber holder <NUM> can include a second holder <NUM> having a second upper surface <NUM> and a second lower surface <NUM>. <FIG> also illustrates the second holder <NUM>. The second lower surface <NUM> is operably attached to the first holder <NUM>. The second holder <NUM> can rotate with respect to the first holder <NUM> at a pivot point <NUM>. The second holder <NUM> can be attached to the first holder <NUM> through various means, e.g., screws <NUM>. The second holder <NUM> can be fixed to the first holder <NUM> after alignment of optical fibers <NUM> by screws <NUM>. The second holder <NUM> can have any shape. For example, the second holder <NUM> can be rectangular, circular, triangular, or any shape. The second holder <NUM> can be made of any suitable material, e.g., plastics, metals, or alloys. The metals can be any metal, e.g., Aluminum, Stainless steel, etc..

In some embodiments, second holder <NUM> includes a first beam <NUM> having a first end <NUM>' and a second end <NUM>". The second holder <NUM> can include a first curved piece <NUM> being attached to the first end <NUM>' and the second end <NUM>" of the first beam <NUM>. In addition, the second holder <NUM> can include a second curved piece <NUM> being attached to the first beam <NUM> at an opposite side of the first beam <NUM> from the first curved piece <NUM>. Further, the second holder <NUM> can include a second beam <NUM> being attached to the first curved piece <NUM> and the first beam <NUM>. Second beam <NUM> can be perpendicular to the first beam <NUM>.

As <FIG> illustrate, the optical fiber holder <NUM> can include a third holder <NUM> having a first portion <NUM> and a second portion <NUM>. <FIG> also illustrates the third holder <NUM>. The first portion <NUM> can include a plurality of holes <NUM> therethrough. The plurality of holes are configured to receive a respective plurality of optical fibers <NUM>. Each hole of the plurality of holes <NUM> can include a respective end cap of the plurality of end caps <NUM> (shown in <FIG>). The plurality of end caps <NUM> are configured to rotate and translate in the plurality of holes <NUM>.

In some embodiments, the first portion <NUM> of the third holder <NUM> includes a planar top piece <NUM>. The planar top piece <NUM> can have any shape. In some embodiments, the planar top piece <NUM> has a rectangular shape. The first portion <NUM> of the third holder <NUM> can have a planar bottom piece <NUM>. The planar bottom piece <NUM> can have any shape. In some embodiments, the planar bottom piece <NUM> has a rectangular shape. The planar top piece <NUM> can have a first corner <NUM>, a second corner <NUM>, a third corner <NUM>', and a forth corner <NUM>'. A length between the first corner <NUM> and second corner <NUM> is greater than a length between the first corner <NUM> and the third corner <NUM>'. Also, the length between the first corner <NUM> and second corner <NUM> is equal to a length between the third corner <NUM>' and the fourth corner <NUM>'. The planar bottom piece <NUM> can be attached to the planar top piece <NUM> to define the plurality of holes <NUM> therethorugh. The plurality of holes <NUM> are located on a plane perpendicular to a virtual Y-axis. The Y-axis is shown in <FIG> and is defined from the first upper surface <NUM> to the first lower surface <NUM>. Four screws <NUM> adjust the planar bottom piece <NUM> to the planar top piece <NUM> of the first portion <NUM> of the third holder <NUM> at the four corners <NUM>, <NUM>', <NUM>, <NUM>'.

Referring to <FIG>, the second portion <NUM> of the third holder <NUM> can include a third beam <NUM> having a first end <NUM> and a second end <NUM>. The first end <NUM> of the third beam <NUM> can be attached to the planar bottom piece <NUM> of the third holder <NUM> and the second end <NUM> can be attached to a first hollow rectangular piece <NUM> and a second hollow rectangular piece <NUM>. The first and second hollow rectangular pieces <NUM>, <NUM> can be located at opposite sides of the third beam <NUM> and can be in a same plane as the third beam <NUM>.

One of the purposes of the two hollow rectangular pieces <NUM>, <NUM> is to secure the optical fibers <NUM> to them for additional support as optical fibers <NUM> are brittle.

The third holder <NUM> can include a plurality of protrusions <NUM>, <NUM>', and <NUM>. In some embodiments, the third holder <NUM> includes a first protrusion <NUM>, a second protrusion <NUM>', and a third protrusion <NUM>. As shown in <FIG>, the first protrusion <NUM> is located at the second end <NUM> of the third beam <NUM>. The second protrusion <NUM>' and the third protrusion <NUM> are connected to the planar bottom piece <NUM> at the first corner <NUM> and the second corner <NUM> respectively. The protrusions <NUM>, <NUM>', <NUM> are operably coupled to the second holder <NUM> and are configured to enable the third holder <NUM> to move.

In some embodiments, the three protrusions <NUM>, <NUM>' and <NUM> connect the third holder <NUM> to the second holder <NUM> through linear adjusters <NUM> as described below.

<FIG> illustrate a linear adjuster <NUM> that connects the third holder <NUM> to the second holder <NUM>. The linear adjuster <NUM> consists of a threaded adjuster body <NUM> which contacts the second holder <NUM> and is free to rotate at this contact. The item to be adjusted contains a threaded interface which matches the thread of the adjuster body <NUM>. That is, the third holder <NUM> contains a threaded interface which matches the thread of the adjuster bodies. The threaded adjuster body <NUM> is typically slotted like a collet such that a wedge <NUM> may be driven into the body <NUM> to expand it outward, locking the adjuster threads into the adjusted item threads. The wedge <NUM> may be formed by creating a separate conical part with a through hole feature that allows a fastener <NUM> to pass through its central axis, washer <NUM>, spherical washer <NUM>, and threads into the mounting interface, e.g., second holder <NUM>.

In practice, the adjuster body <NUM> is rotated to create a linear adjustment between the adjusted item <NUM>, i.e., third holder <NUM>, and mounting interface <NUM>, i.e., second holder <NUM>. After desired adjustments are made to all three linear adjusters in the protrusions <NUM>, <NUM>', <NUM>, the adjuster body <NUM> is constrained from rotation, typically with a tool, and the fastener <NUM> is then torqued which wedges the conic into the adjuster body <NUM>, causing the body <NUM> to expand and creating a high-friction thread lock between the adjuster body <NUM> and the adjusted item <NUM>.

The present disclosure can provide the alignment of the plurality of the optical fibers <NUM> in <NUM> degrees of freedom. Translation of the fibers as an array, i.e., plurality of fibers <NUM>, along Y-axis only, occurs at times the first protrusion <NUM>, the second protrusion <NUM>', and the third protrusion <NUM> all move along the virtual Y-axis in a same direction. Translation of the plurality of fibers <NUM> (as an array) along the X-axis only, occurs through the movement of the optical fiber holder <NUM> in the virtual X-axis. Translation of the plurality of fibers <NUM> (as an array) along the Z-axis only, occurs through the movement of the optical fiber holder <NUM> in the virtual Z-axis. After the alignment of the plurality of fibers <NUM> through movement of the optical fiber <NUM> in the X-axis and/or the Z-axis, the optical fiber holder <NUM> is fixed to the working station <NUM> by screws <NUM> as explained above.

The rotation of the plurality of the optical fibers <NUM> about the virtual Y-axis only, occurs by rotation of the second holder <NUM> about the first holder <NUM> at the pivot point <NUM>. The rotation of the plurality of the optical fibers <NUM> about the virtual X-axis occurs by movement/adjustment of the linear adjuster <NUM> of the first protrusion <NUM>. The rotation of the plurality of the optical fibers <NUM> about the virtual Z-axis occurs by adjustment of the linear adjuster <NUM> of the second protrusion <NUM>' and the third protrusion <NUM> equal amounts but in opposite directions.

In some embodiments, the translation of the plurality of fibers <NUM> along Y-axis and rotation about the X-axis occurs by adjustment of the linear adjusters <NUM> of the second protrusion <NUM>' and the third protrusion <NUM> equal amount and in the same directions (both up or both down). In some embodiments, the plurality of optical fibers <NUM> translates along the Y-axis and also rotates about the X-axis and Z-axis, only by adjusting the linear adjuster <NUM> of the second protrusion <NUM>' or the third protrusion <NUM>.

Further, the present disclosure provides the alignment of each optical fiber of the plurality of optical fibers <NUM> in <NUM> degrees of freedom. That is, each optical fiber can be aligned individually in <NUM> degrees of freedom. The rotation of each optical fiber about the virtual Y-axis and the virtual Z-axis is provided through precision tooling. The translation of each optical fiber along the virtual X-axis and Z-axis is provided by precision tooling too.

The rotation of optical fibers about the X-axis can be performed by screws shown in <FIG> illustrate side view, front view and close up views of the optical fiber holder <NUM>. As shown, each optical fiber of the plurality of the optical fiber <NUM> is secured in their respective hole <NUM> by four screws <NUM>, <NUM>, <NUM>, <NUM> between the planar top piece <NUM> and the planar bottom piece <NUM> of the first portion <NUM> of the third holder <NUM>. The four screws <NUM>, <NUM>, <NUM>, <NUM> are in contact with the end caps of the optical fibers. To align the optical fibers individually, the screws <NUM>, <NUM>, <NUM>, <NUM> could be moved up or down (along the virtual Y-axis) to adjust the fibers to a desired alignment. After the optical fibers are aligned in holes <NUM>, adhesive or bond material <NUM> will be injected through holes <NUM>, <NUM>, <NUM> and <NUM> to hold the optical fibers in the desired position. <FIG> illustrates the front view of the optical fibers in their respective holes <NUM> being surrounded by bond material <NUM>.

The rotation of the optical fiber about the virtual X-axis occurs by adjustment of the screws <NUM>, <NUM>, <NUM>, and <NUM> along the virtual Y-axis in equal amount, but the screws <NUM> and <NUM> are moved in opposite direction with respect to the screws <NUM> and <NUM>. The translation of the optical fiber along the virtual Y-axis occurs by adjustment of the <NUM>, <NUM>, <NUM>, and <NUM> along the virtual Y-axis in equal amount and in same direction.

Referring to <FIG>, after alignment of fibers, each of the plurality of fibers <NUM> will be secured in a respective hole of the plurality of holes <NUM> with an adhesive material. As a result, the adhesive material will hold the plurality of optical fibers <NUM> in their respective holes <NUM> after alignment.

<FIG> illustrates various optical fibers <NUM> with end caps <NUM>. The end caps <NUM>, which are attached to the optical fibers <NUM>, include optical glasses, e.g., fused silica, and are encased in a protective metal housing, e.g., stainless steel surgical tubing, etc. The end caps <NUM> can be placed in the holes <NUM> of first portion <NUM> of the third holder <NUM>. The holes <NUM> can include the whole length of end caps <NUM> or a portion of the end caps <NUM>. In some embodiments, the holes <NUM> can include the end caps <NUM> and some portion of the optical fibers <NUM>.

Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

Whereas many alterations and modifications of the disclosure will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that the particular embodiments shown and described by way of illustration are in no way intended to be considered limiting. Further, the subject matter has been described with reference to particular embodiments, but variations of the disclosure will occur to those skilled in the art. It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present disclosure.

Claim 1:
An optical fiber holder (<NUM>), suitable for use in high energy laser, HEL, systems, comprising:
a first holder (<NUM>) having a first upper surface (<NUM>) and a first lower surface (<NUM>) and configured to be in contact with a working station (<NUM>) through the first lower surface (<NUM>);
a second holder (<NUM>) having a second upper surface (<NUM>) and a second lower surface (<NUM>), the second holder (<NUM>) being operably attached to the first holder (<NUM>) through the second lower surface (<NUM>), the second holder (<NUM>) being configured to rotate with respect to the first holder (<NUM>); and
a third holder (<NUM>) including a first portion (<NUM>) having a plurality of holes (<NUM>) therethrough, each hole configured to receive a respective optical fiber of a plurality of optical fibers (<NUM>), the first portion (<NUM>) having a plurality of protrusions (<NUM>, <NUM>', <NUM>) operably coupled to the second holder (<NUM>) and configured to enable the third holder (<NUM>) to move with respect to the second holder (<NUM>);
wherein each hole (<NUM>) is configured, when a respective optical fiber of the plurality of optical fibers (<NUM>) is received, to allow the respective optical fiber of the plurality of optical fibers (<NUM>) that has an endcap (<NUM>) to rotate and translate in such hole (<NUM>) of the plurality of holes (<NUM>).