Connection assembly for feeding optical fiber

Abstract

The invention relates to a connection assembly for feeding an optical fiber. In some implementations, the connection assembly includes a sleeve body defining a sleeve, a first electrical contact element embedded in the sleeve body, and a second electrical contact element embedded in the sleeve body, where the sleeve body electrically isolates the first electrical contact element from the second electrical contact element. The connection assembly may include a first wire electrically connected to the first electrical contact element within the sleeve body and a second wire electrically connected to the second electrical contact element within the sleeve body.

Description

[0001] Cross - Reference to Related Applications

[0002] This patent application claims the priority of U.S. Provisional Patent Application No. 63 / 604,525, entitled "CONTACT RING ASSEMBLY", filed on November 30, 2023. The disclosure of the prior application is hereby incorporated by reference in its entirety and made a part of this patent application. Technical Field

[0003] The present disclosure generally relates to a laser and a connection assembly for feeding an optical fiber. Background Art

[0004] An optical fiber laser is a laser in which the active gain medium is an optical fiber doped with an element capable of providing gain (such as erbium, ytterbium, neodymium, dysprosium, praseodymium, thulium, holmium, bismuth, etc.). A high-power optical fiber laser is an optical fiber laser capable of delivering a relatively high output power. For example, the output power of a high-power optical fiber laser can range from several tens of watts to several kilowatts. Summary of the Invention

[0005] In some implementations, a laser system includes a laser source, an output portion of the laser system having a connector, and a feed fiber assembly configured to optically couple the laser source to the output portion of the laser system. The feed fiber assembly may include a cooling assembly configured to be connected to the connector and a connection assembly mounted on the cooling assembly and configured to establish an electrical connection with the connector. The connection assembly may include a sleeve body defining a sleeve, a first electrical contact element embedded in the sleeve body, and a second electrical contact element embedded in the sleeve body, wherein the sleeve body electrically isolates the first electrical contact element from the second electrical contact element.

[0006] In some implementations, a feed fiber assembly includes an optical fiber and a cooling assembly including a housing having a fluid inlet and a fluid outlet, wherein the optical fiber extends through the cooling assembly. The feed fiber assembly may include a connection assembly mounted on the cooling assembly. The feed fiber assembly may include a sleeve body defining a sleeve, a first electrical contact element embedded in the sleeve body, and a second electrical contact element embedded in the sleeve body, wherein the sleeve body electrically isolates the first electrical contact element from the second electrical contact element and wherein the sleeve body electrically isolates the housing from the first and second electrical contact elements.

[0007] In some implementations, a connection component includes a sleeve body defining a sleeve, a first electrical contact element embedded in the sleeve body, and a second electrical contact element embedded in the sleeve body, wherein the sleeve body electrically isolates the first electrical contact element from the second electrical contact element. The connection component may include a first wire electrically connected to the first electrical contact element within the sleeve body and a second wire electrically connected to the second electrical contact element within the sleeve body. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a diagram illustrating an example laser system.

[0009] Figure 2 shows a perspective view of an example connection component.

[0010] Figure 3 is Figure 2 a cross-sectional view of the connection component taken along line A-A.

[0011] Figure 4 is a flowchart of an example process associated with the manufacture of the connection component. DETAILED DESCRIPTION

[0012] The following detailed description of example implementations refers to the accompanying drawings. The same reference numerals in different drawings may identify the same or similar elements.

[0013] Fiber lasers are a class of lasers that offer significant advantages in terms of efficiency and practicality compared to other laser types such as free-space lasers. In a fiber laser, light is guided by an active fiber core that is typically doped with ions of rare-earth elements (such as ytterbium or erbium), and the ions of the rare-earth element provide optical gain. The guiding characteristics of the doped fiber core greatly relax the requirements for optical alignment and allow the length of the gain medium to be increased to several tens or even hundreds of meters, thereby generating a very high achievable optical gain. For example, using double-clad fiber (DCF), fiber lasers can be scaled to kilowatt (kW) power levels.

[0014] The optical output of a high-power fiber laser can be coupled into a delivery fiber that is used to deliver light for applications such as laser cutting, laser welding, etc. Due to the high-power output of the fiber laser, various measures can be taken to address overheating and accidental laser discharge issues. For example, the delivery fiber may include a cooling component (e.g., cooling channels) that provides fluid cooling for the delivery fiber. In addition, the cooling component can be configured to be connected to a connector using an interlock device that prevents operation of the high-power fiber laser when the delivery fiber is disconnected. For example, the cooling component may include electrical contacts (e.g., contact pads or contact rings) that close a circuit to signal that the high-power fiber laser can be activated when engaged with a conductive surface (e.g., pins) of the connector.

[0015] Typically, electrical contacts can be attached to a cooling assembly using a spacer ring system. For example, multiple spacer rings that insulate the electrical contacts from the cooling assembly and from each other can be assembled onto the cooling assembly together with the electrical contacts and associated wires. As an example, the assembly of the spacer rings and electrical contacts can involve sliding a first spacer ring, a first electrical contact, a second spacer ring, a second electrical contact, and a third spacer ring onto the cooling assembly in sequence. Additionally, during the assembly of the spacer rings and electrical contacts, the wires of the electrical contacts pass through the spacer rings. Thus, the assembly of the spacer rings, electrical contacts, and associated wires requires great care, is time-consuming, and is prone to non-compliant assembly.

[0016] Furthermore, during the use of the cooling assembly, improper handling or other mechanical effects of the cooling assembly may cause translation, rotation, or other movement of the spacer rings and electrical contacts. As a result, the electrical contacts may be misaligned, preventing the correct closing of the circuit and / or the correct operation of the high-power fiber laser. Additionally, the electrical contacts may be rotated to such an extent that the wires of the electrical connections are disconnected, resulting in an electrical short circuit and / or an open circuit.

[0017] Some implementations described herein provide an integral connection assembly that can be mounted on a cooling assembly as a single element. In some implementations, the connection assembly includes a sleeve body that defines a sleeve and a set of electrical contact elements embedded in the sleeve body to fix the positions of the electrical contact elements. Additionally, the sleeve body provides electrical isolation between the electrical contact elements and between the electrical contact elements and the cooling assembly. The integral nature of the connection assembly allows for tight control of the positioning of the electrical contact elements on the sleeve body, thereby facilitating the precise alignment of the electrical contact elements. Additionally, the fixing of the positions of the electrical contact elements is capable of resisting movement or other motion that would otherwise be caused by improper operation or other mechanical effects on the cooling assembly. Thus, even during many uses, the connection assembly can consistently make a reliable electrical connection with the connector. Additionally, the connection assembly can be stored in inventory as a single element, thereby reducing the need for excessive and cumbersome parts inventory.

[0018] Figure 1 is a diagrammatic example of a laser system 100. As shown, the laser system 100 includes a laser source 102, a laser system output 104, and a feed fiber assembly 106.

[0019] The laser source 102 may include any device or combination of devices that generate laser light. For example, the laser source 102 may include a single laser or a group of lasers coupled into a single output. In some implementations, the laser source 102 may include a fiber laser (e.g., including an optical cavity with a fiber doped with an element capable of providing optical gain, such as erbium or ytterbium) and / or a fiber amplifier. The fiber laser may be a high-power fiber laser (e.g., having an output power of several tens of watts to several kilowatts).

[0020] The laser system output section 104 may include an optical output section of the feed fiber assembly 106 and / or a connector 108 (e.g., a mechanical structure) configured to hold the feed fiber assembly 108 in a specific position for laser applications such as laser cutting, laser drilling, laser welding, etc. The connector 108 may be configured to physically and / or electrically connect and disconnect from the feed fiber assembly 106. For example, the connector 108 may include a conductive surface 110 (e.g., a set of conductive pins) configured to facilitate detection of the connection between the feed fiber assembly 106 and the connector 108, as described below. In some implementations, the connector 108 may include a socket, a port, etc., into which the feed fiber assembly 106 may be inserted. In some implementations, the connector 108 may include one or more lenses, one or more mirrors, and / or other optical elements or devices configured to direct and / or focus light onto a target.

[0021] The feed fiber assembly 106 may include a fiber 112 and a protective sheath 114 surrounding a portion of the fiber 112. The feed fiber assembly 106 may optically couple the laser source 102 to the laser system output section 104. For example, a first end (e.g., a rear end) of the feed fiber assembly 106 may be optically coupled to the laser source 102. As an example, the fiber 112 may be optically coupled to the output of the laser source 102 (e.g., the output of a fiber laser). A second end of the feed fiber assembly 106 may terminate at a cooling assembly 116 (e.g., a cooling channel or a water channel). For example, at the second end of the feed fiber assembly 106, the fiber 112 may extend through the cooling assembly 116. The cooling assembly 116 may be configured to provide cooling to the fiber 112 and / or the connector 108. Additionally, the cooling assembly 116 may be configured to connect to the connector 108.

[0022] The cooling assembly 116 can include a housing 118 (e.g., which surrounds a portion of the optical fiber 112). The housing 118 can be configured to mate with the connector 108. For example, the housing 118 can be cylindrical and can taper inwardly towards an end of the housing 118 to facilitate insertion of the cooling assembly 116 into a socket, port, etc. of the connector 108. The housing 118 can have a fluid inlet 120 that enters into the housing 118 and a fluid outlet 122 that exits from the housing 118. The fluid inlet 120 can be coupled to a fluid conduit 124 (e.g., a hose) that is configured to supply fluid (e.g., a liquid such as water or a gas such as air) to the fluid inlet 120. The fluid outlet 122 can be coupled to a fluid conduit 124 (e.g., a hose) that is configured to direct fluid out of the housing 118. A fluid path (not shown) can extend within the housing 118 between the fluid inlet 120 and the fluid outlet 122. The fluid path can be configured to thermally interact with the optical fiber 112 (e.g., to cool the optical fiber 112). In some implementations, the housing 118 can be constructed of a conductive material such as a metal or metal alloy.

[0023] The feed optical fiber assembly 106 can include a connection assembly 126 mounted on the cooling assembly 116. For example, the connection assembly 126 can be positioned on the housing 118. As an example, the housing 118 can have a recessed area (e.g., extending circumferentially around the housing 118), and the connection assembly 126 can be positioned within the recessed area (e.g., to limit the connection assembly 126 from slipping off the cooling assembly 116). When the cooling assembly 116 is connected to the connector 108, the connection assembly 126 can establish an electrical connection with the conductive surface 110. The electrical connection can close a circuit, thereby allowing the laser source 102 to operate.

[0024] As described above, Figure 1 is provided as an example. Other examples can be different from those regarding Figure 1 described.

[0025] Figure 2 A perspective view of an example connection assembly 126 is shown. In Figure 2 the connection assembly 126 is shown mounted on the housing 118 of the cooling assembly 116 (shown in dashed lines).

[0026] The connection assembly 126 includes a sleeve body 128 (e.g., a molded sleeve body) and a set of electrical contact elements 130 (e.g., a first electrical contact element 130 and a second electrical contact element 130) embedded within the sleeve body 128. In some implementations, the electrical contact elements 130 can include contact rings (e.g., annular electrical contacts).

[0027] The sleeve body 128 defines the sleeve. For example, the sleeve body 128 includes a side wall (e.g., which is continuous), and the side wall defines an opening passing through the sleeve body 128 (e.g., the sleeve body 128 is open at both ends of the sleeve body 128). For example, the sleeve body 128 may have the shape of a hollow cylinder or another hollow geometry. Thus, the sleeve body 128 has an inner surface (e.g., surrounding the opening passing through the sleeve body 128) and an outer surface.

[0028] The electrical contact element 130 is embedded in the sleeve body 128. Embedding the electrical contact element 130 in the sleeve body 128 can fix the position of the electrical contact element 130 relative to the sleeve body 128. The electrical contact element 130 may be embedded in the sleeve body 128 such that the electrical contact element 130 is exposed at the outer surface of the sleeve body 128 (e.g., so as to allow the electrical contact element 130 to electrically contact the conductive surface 110 of the connector 108). In addition, the electrical contact element 130 may be embedded in the sleeve body 128 such that a certain area of the sleeve body 128 is located between the inner surface of the sleeve body 128 and the electrical contact element 130 (e.g., the electrical contact element 130 is not exposed at the inner surface of the sleeve body 128, thereby restricting the electrical contact between the electrical contact element 130 and the metal housing 118 of the cooling assembly 116), as Figure 3 shown.

[0029] The sleeve body 128 may be made of an electrically isolating material (e.g., an electrically insulating material). In addition, the material may be rigid. In addition, the material may be a thermosetting material. For example, the sleeve body 128 may be made of polyoxymethylene (POM) or another plastic. In some implementations, the sleeve body 128 may include a polymer matrix in which the electrical contact element 130 is embedded. For example, the sleeve body 128 may be an overmolding on the electrical contact element 130. The electrical contact element 130 may be made of a conductive material, such as a metal or a metal alloy (e.g., copper). Thus, the sleeve body 128 can electrically isolate the first electrical contact element 130 from the second electrical contact element 130. In addition, the sleeve body 128 can provide electrical isolation between the electrical contact element 130 and the housing 118 of the cooling assembly 116.

[0030] In some implementations, the connection assembly 126 may employ one or more locking features configured to restrict rotation of the sleeve body 128 about the housing 118 of the cooling assembly 116. For example, when the connection assembly 126 is positioned on the housing 118, the holes through the sleeve body 128 may be configured to align with holes or cavities in the housing 118 of the cooling assembly 116. The connection assembly 126 may include pins that can be inserted into the holes through the sleeve body 128 and into the holes or cavities in the housing 118 to lock the position of the connection assembly 126 on the housing 118. As another example, the sleeve body 128 may have a non-circular cross-section (e.g., D-shaped cross-section, square cross-section, oval cross-section, etc.), and the area of the housing 118 where the connection assembly 126 is located (e.g., the recessed area of the housing 118) may have a corresponding cross-sectional shape. Thus, when the connection assembly 126 is positioned on the housing 118, the non-circular cross-sections of the sleeve body 128 and the housing 118 restrict rotation of the connection assembly 126.

[0031] The connection assembly 126 is a monolithic component that can be mounted on the cooling assembly 116 as a single element. The monolithic nature of the connection assembly 126 allows for tight control of the positioning of the electrical contact element 130 on the sleeve body 128, thereby facilitating precise alignment between the electrical contact element 130 and the conductive surface 110 of the connector 108. For example, the connection between the cooling assembly 116 and the connector 108 can complete the circuit via contact of the electrical contact element with the conductive surface 110.

[0032] In addition, the monolithic nature of the connection assembly 126 fixes the position of the electrical contact element 130 relative to the sleeve body 128. In this way, the electrical contact element 130 can resist movement or other motion that would otherwise result from improper operation of the cooling assembly 116 or other mechanical influences. Thus, even over many uses, the connection assembly 126 can consistently make a reliable electrical connection with the connector 108. In addition, the connection assembly 126 can be stocked as a single element, thereby reducing the need for excessive and burdensome parts inventory.

[0033] As described above, Figure 2 is provided as an example. Other examples may be different from those Figure 2 described.

[0034] Figure 3 is Figure 2 A cross-sectional view of the connection assembly 126 taken along line A-A.

[0035] As shown in the figure, the connection assembly 126 may include a set of wires 132 (e.g., a first wire 132 and a second wire 132). The wires 132 may include any type of conductive connector. The wires 132 extend along the sleeve body 128 and are electrically connected to the corresponding electrical contact elements 130. For example, the electrical connection between the wires 132 and the electrical contact elements 130 may be buried in the sleeve body 128 between the outer surface and the inner surface of the sleeve body 128. The wires 132 may extend through the sleeve body 128 (e.g., from the position where the wires 132 are electrically connected to the electrical contact elements 130) and protrude from one end of the sleeve body 128 (e.g., the wires 132 may protrude from the same end of the sleeve body 128).

[0036] As described above, Figure 3 is provided as an example. Other examples may be different from those Figure 3 described.

[0037] Figure 4 is a flowchart of an example process 400 associated with the manufacture of the connection assembly. In some implementations, Figure 4 one or more process blocks of are performed by a manufacturing device (such as an injection molding device).

[0038] As Figure 4 shown, the process 400 may include placing a first electrical contact element and a second electrical contact element in a first mold part (block 410). For example, the first mold part may include retaining features that hold the first electrical contact element and the second electrical contact element in position in the first mold part. When placed in the first mold part, the first electrical contact element may be spaced apart from the second electrical contact element. In some implementations, the process 400 includes placing a first wire in the first mold part to make electrical contact with the first electrical contact element and placing a second wire in a second mold part to make electrical contact with the second electrical contact element. The electrical connection between the wire and the electrical contact element may be formed by solder or a conductive adhesive, by winding the wire around the electrical contact element, by bringing the wire into contact with the electrical contact element, and so on.

[0039] As Figure 4 further shown, the process 400 may include joining the second mold part to the first mold part to produce a mold (block 420). In some implementations, the second mold part may also include retaining features that hold the first electrical contact element and the second electrical contact element in position. In some implementations, the first wire and the second wire may extend outside the mold (e.g., via holes in the first mold part and / or the second mold part).

[0040] As Figure 4Further shown, process 400 may include injecting a molding material into a mold to overmold a first electrical contact element and a second electrical contact element with the molding material (block 430). The molding material may also encapsulate the wire. The molding material may include an electrically insulating material, such as plastic, as described herein. Injecting the molding material into the mold may produce a connection assembly (e.g., connection assembly 126). For example, the mold may be configured to form the molding material into a sleeve body, wherein the first electrical contact element and the second electrical contact element (and the wire) are embedded in the sleeve body, as described herein.

[0041] In some implementations, process 400 may include curing the molding material injected into the mold. In some implementations, process 400 may include separating a first mold part and a second mold part and removing the connection assembly from the mold.

[0042] Although Figure 4 example blocks of process 400 are shown, in some implementations, process 400 includes more blocks, fewer blocks, or different blocks than Figure 4 shown.

[0043] The foregoing disclosure provides illustration and description, but is not intended to be exhaustive or to limit implementations to the precise forms disclosed. Modifications and variations may be made in light of the foregoing disclosure, or may be acquired from the practice of implementations. Additionally, any implementations described herein may be combined, unless the foregoing disclosure expressly provides a reason that one or more implementations cannot be combined.

[0044] Although specific combinations of features are recited in the claims and / or disclosed in the specification, these combinations are not intended to limit the disclosure of various implementations. In fact, many of these features may be combined in ways not specifically recited in the claims and / or not expressly disclosed in the specification. Although each dependent claim listed below may directly depend on only one claim, the disclosure of various implementations includes each dependent claim in combination with every other claim in the claim set. As used herein, the phrase "at least one" in reference to a list of items refers to any combination of those items, including a single member. For example, "at least one of a, b, or c" is intended to cover a, b, c, a - b, a - c, b - c, and a - b - c, as well as combinations of multiple occurrences of the same item.

[0045] Unless expressly stated otherwise, no element, act, or instruction used herein shall be construed as critical or essential. Additionally, as used herein, the articles "a" and "an" are intended to include one or more items and may be used interchangeably with "one or more." Further, as used herein, the article "the" is intended to include one or more items referenced in conjunction with the article "the" and may be used interchangeably with "one or more." Additionally, the term "set" as used herein is intended to include one or more items (e.g., related items, unrelated items, or a combination of related and unrelated items) and may be used interchangeably with "one or more." If only one item is intended, the phrase "only one" or similar language is used. Additionally, as used herein, the terms "having," "has," "containing," etc. are intended to be open-ended terms. Further, unless expressly stated otherwise, the term "based on" is intended to mean "at least partially based on." Additionally, as used herein, the term "or" is inclusive when used in series and may be used interchangeably with "and / or" unless expressly stated otherwise (e.g., if used in conjunction with "any of..." or "only one of...").

Claims

1. A laser system comprising: Laser source; A laser system output portion having a connector; as well as a feeding fiber assembly configured to optically couple the laser source to the laser system output, the feeding fiber assembly comprising: a cooling assembly configured to be connected to the connector; and A connection component, mounted on the cooling component and configured to establish an electrical connection with the connector, the connection component comprising: A sleeve body, defining the sleeve; a first electrical contact element embedded in the sleeve body; and a second electrical contact element, embedded in the sleeve body, The sleeve body electrically isolates the first electrical contact element from the second electrical contact element.

2. The laser system of claim 1 , wherein the cooling assembly comprises a housing, a fluid inlet into the housing, a fluid outlet from the housing, and a fluid path within the housing, the fluid path being located between the fluid inlet and the fluid outlet.

3. The laser system of claim 2, wherein the sleeve body has a non-circular cross-section corresponding to a non-circular cross-section of a region of the housing on which the connection assembly is positioned.

4. The laser system of claim 2, wherein the sleeve body electrically isolates the first electrical contact element and the second electrical contact element from the housing.

5. The laser system of claim 1, wherein the feed fiber assembly comprises an optical fiber extending through the cooling assembly.

6. The laser system of claim 1 , wherein the connector comprises a conductive surface, and The connection between the cooling assembly and the connector is used to complete an electrical circuit via the contact between the first electrical contact element and the second electrical contact element and the conductive surface.

7. The laser system of claim 1, wherein the connection assembly further comprises: a first wire electrically connected to the first electrical contact element in the sleeve body, wherein the first wire extends through the sleeve body and protrudes from the sleeve body at an end of the sleeve body; as well as a second wire electrically connected to the second electrical contact element within the sleeve body, The second wire extends through the sleeve body and protrudes from the sleeve body at the end of the sleeve body.

8. A feeding optical fiber assembly, comprising: optical fiber; A cooling assembly comprising a housing having a fluid inlet and a fluid outlet, wherein the optical fiber extends through the cooling assembly; as well as A connecting assembly is mounted on the cooling assembly, and the connecting assembly comprises: A sleeve body, defining the sleeve; a first electrical contact element embedded in the sleeve body; and a second electrical contact element, embedded in the sleeve body, wherein the sleeve body electrically isolates the first electrical contact element from the second electrical contact element, and The sleeve body electrically isolates the housing from the first electrical contact element and the second electrical contact element.

9. The fiber feeder assembly of claim 8, further comprising a jacket surrounding a portion of the optical fiber.

10. The fiber feeding assembly of claim 8, wherein the housing has a recessed area, and The connecting assembly is positioned in the recessed area.

11. The fiber feeding assembly of claim 8, wherein the sleeve body has an inner surface and an outer surface, wherein the first electrical contact element and the second electrical contact element are exposed at the outer surface, and The region of the sleeve body is located between the inner surface and the first electrical contact element and the second electrical contact element.

12. The fiber feed assembly of claim 8, wherein the sleeve body has a non-circular cross-section corresponding to a non-circular cross-section of a region of the housing on which the connection assembly is positioned.

13. The fiber feeding assembly of claim 8, wherein the connection assembly further comprises: a first wire electrically connected to the first electrical contact element in the sleeve body, wherein the first wire extends through the sleeve body and protrudes from the sleeve body at an end of the sleeve body; as well as a second wire electrically connected to the second electrical contact element within the sleeve body, The second wire extends through the sleeve body and protrudes from the sleeve body at the end of the sleeve body.

14. The fiber feeding assembly of claim 8, wherein the sleeve body is an overmold over the first electrical contact element and the second electrical contact element.

15. A connection assembly comprising: A sleeve body, defining the sleeve; a first electrical contact element embedded in the sleeve body; a second electrical contact element, embedded in the sleeve body, wherein the sleeve body electrically isolates the first electrical contact element from the second electrical contact element; a first wire electrically connected to the first electrical contact element within the sleeve body; as well as A second wire is electrically connected to the second electrical contact element in the sleeve body.

16. The connection assembly of claim 15, wherein the sleeve body is an overmold over the first and second electrical contact elements.

17. The connection assembly of claim 15, wherein the sleeve body has a non-circular cross-section.

18. The connection assembly of claim 15, wherein the first wire extends through the sleeve body and protrudes from the sleeve body at an end of the sleeve body, and the second wire extends through the sleeve body and protrudes from the sleeve body at the end of the sleeve body.

19. The connection assembly of claim 15, wherein the first electrical contact element is a first contact ring and the second electrical contact element is a second contact ring.

20. The connection assembly of claim 15, wherein the sleeve body has an inner surface and an outer surface, wherein the first electrical contact element and the second electrical contact element are exposed at the outer surface, and The region of the sleeve body is located between the inner surface and the first electrical contact element and the second electrical contact element.

Images