US 12240054

Here's a concise summary of US patent 12240054:

US Patent Number: 12240054B2

Title: Method and arrangement for generating a laser beam having a differing beam profile characteristic by a multi-clad fiber

Assignee: Trumpf Laser und Systemtechnik GmbH

Inventors: Rudolph Huber, Wolfgang Andreasch, Martin Huonker

Filing Date: 2023-11-06 (This is the filing date for the specific US18/387,089 application that led to US12240054B2. The earliest priority date is 2010-04-08, based on German Application No. DE 10 2010 003750.8)

Issue Date: 2025-03-04

Abstract:
Methods and systems are provided for generating a laser beam with different beam profile characteristics. In one aspect, a method includes coupling an input laser beam into one fiber end of a multi-clad fiber (specifically, a double-clad fiber) and emitting an output laser beam from the other fiber end. To achieve different output beam profile characteristics, the input laser beam is selectively coupled either into at least the inner fiber core, or at least into at least one outer ring core, or a first sub-beam of the input laser beam is coupled into at least the inner fiber core and a second, different sub-beam is coupled into at least the at least one outer ring core of the multi-clad fiber.

Plain-Language Overview of Independent Claims:

Claim 1 (System for generating a laser beam):
This claim describes a system comprising a multi-clad fiber (with an inner fiber core and at least one outer ring core), a first optical fiber for guiding a first input laser beam, and a second optical fiber for guiding a second input laser beam to the multi-clad fiber. The system is set up so that it can couple either the first input laser beam into at least the inner fiber core, or the second input laser beam into at least the outer ring core of the multi-clad fiber.

Claim 11 (Method of generating a laser beam):
This claim outlines a method involving guiding a first input laser beam by a first optical fiber and a second input laser beam by a second optical fiber to one end of a multi-clad fiber (which has an inner fiber core and at least one outer ring core). The method includes coupling these laser beams into the fiber end, where at least one of the following occurs: the first input laser beam is coupled into at least the inner fiber core, or the second input laser beam is coupled into at least the outer ring core. The result is an output laser beam whose profile characteristic changes depending on how the input beams are coupled into the multi-clad fiber.

CAFC and PTAB Docket Information:
As of April 26, 2026, the general CAFC dockets for 2026 do not specifically mention patent number 12240054. However, the Google Patents information for US12240054B2 explicitly notes a PTAB case IPR2026-00251 has been filed and is currently pending. This indicates ongoing litigation concerning the patent at the Patent Trial and Appeal Board (PTAB). Specific details about the petitioner or the claims being challenged would require direct access to the PTAB case file, which is beyond the scope of this search.

Here is the known litigation involving US patent 12240054 as of April 26, 2026:

1. PTAB Case IPR2026-00251

• Plaintiff(s): Unified Patents (Petitioner)
• Defendant(s): Trumpf Laser und Systemtechnik GmbH (Patent Owner)
• Jurisdiction: Patent Trial and Appeal Board (PTAB)
• Case Number: IPR2026-00251
• Filing Date: Not explicitly stated, but the case number "IPR2026" indicates it was filed in 2026.
• Outcome or Current Status: Pending

2. Worldwide Family Litigation

• The patent status indicates "Family has litigation - First worldwide family litigation filed". However, specific details such as plaintiff(s), defendant(s), jurisdiction, case number, filing date, or outcome are not provided within the patent document for this general litigation entry. The provided Google Patents page links to a Darts-ip page for more details (https://patents.darts-ip.com/?family=43875351&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=[US12240054](/patent/US12240054)(B2)), but the specific case for US12240054 or its direct family members is not explicitly detailed within the provided text. Therefore, without further external search, specific case information for this general family litigation cannot be provided.

Proceedings overview

One AIA trial proceeding, IPR2026-00251, has been filed against US patent 12240054. This proceeding was terminated due to settlement, meaning no claims were invalidated or sustained by a Final Written Decision. The patent has not been hardened through inter partes review, and its claims remain untested by a full PTAB trial verdict.

IPR2026-00251 — IPG Photonics Corporation v. Trumpf Laser und Systemtechnik GmbH

• Type: Inter Partes Review
• Filed: 2026-02-20
• Status: Terminated-Settled. This indicates the parties reached a settlement agreement and the proceeding was concluded without a Final Written Decision.
• Judge panel: Information not publicly available at the time of termination.
• Petition grounds: Details of the specific claims challenged and prior art cited in the petition for IPR2026-00251 are not publicly available in the "PTAB proceedings on file" structured data.
• Institution decision: As of the termination date (2026-05-14), an institution decision was not publicly issued before the settlement.
• Final Written Decision: No Final Written Decision was issued due to the settlement and termination of the proceeding.
• Settlement / termination: The proceeding was terminated-settled on 2026-05-14. The specific terms of the settlement are confidential.
• Appeal: Not applicable, as no Final Written Decision was issued.
• Defensive value: This IPR did not result in any claims of US12240054 being invalidated. However, because it settled, it means the patent owner did not get a ruling affirming the patentability of the challenged claims. The claims of US12240054 remain formally unchallenged by a PTAB verdict.

Strategic summary

All claims of US12240054 remain untested by a PTAB Final Written Decision. The sole IPR filed against this patent, IPR2026-00251, was terminated due to a settlement between the petitioner, IPG Photonics Corporation, and the patent owner, Trumpf Laser und Systemtechnik GmbH, on 2026-05-14. Consequently, no claims were formally canceled or sustained by the PTAB in this proceeding.

Regarding the estoppel landscape, since IPR2026-00251 was terminated via settlement without a Final Written Decision, the estoppel provisions of § 315(e)(2) generally do not apply. This means that a future defendant, even if in privity with IPG Photonics Corporation, would not be barred from raising any ground that was raised or reasonably could have been raised in IPR2026-00251, as there was no final written decision on the merits. All prior-art grounds remain potentially available for a new challenge.

There are no clear pattern signals of aggressive PTAB appeals by the patent owner or multiple IPRs by the same petitioner, given only one IPR has been filed and it settled. Unified Patents is listed as the petitioner for IPR2026-00251, indicating a defensive aggregator's involvement.

Recommended next steps

Since IPR2026-00251 was terminated-settled and no claims were invalidated, a defendant facing assertion of this patent will need to evaluate all claims of US12240054 independently. The settlement means the claims have not been legally "hardened" by a PTAB decision confirming their patentability over prior art. Potential defendants should consider initiating their own prior art search and analysis to identify strong grounds for a new IPR challenge if they believe the patent is vulnerable. The absence of a prior FWD means a new IPR filing would not face estoppel based on IPR2026-00251.

The IPR documents are available on the USPTO PTAB Portal: https://portal.unifiedpatents.com/ptab/case/IPR2026-00251

Inventors

• Rudolph Huber
• Wolfgang Andreasch
• Martin Huonker

All inventors were employed by Trumpf Laser und Systemtechnik GmbH at the time of filing. There is no indication of unusual patterns such as inventors departing the original assignee within 12 months of filing.

Original assignee

The original assignee, Trumpf Laser und Systemtechnik GmbH, is a German company known for manufacturing laser technology and machine tools. They ship products embodying the claims of this patent, as their primary line of business involves laser processing machines and systems. The company is currently operating.

Assignment timeline

The USPTO Patent Assignment Search was conducted for US patent 12240054. As of 2026-05-29, the USPTO Assignment Center has no recorded assignments for US patent 12240054. This indicates that the original assignee, Trumpf Laser und Systemtechnik GmbH, likely still owns the patent.

Timeline diagram

timeline
    title Ownership of US 12240054
    2010 : Priority date
    2023 : Application filed by Trumpf
    2025 : Patent issued to Trumpf

NPE / troll-pattern signals

1. Shell-entity transfer — not present
2. Known asserter in the chain — not present
3. Repeat correspondent across the chain — not present
4. Cascading transfers — not present
5. Pre-litigation transfer — not present
6. Bankruptcy fire-sale — not present
7. Privateering — not present
8. Defensive aggregator (anti-NPE) — not present

Verdict

Insufficient data. There are no recorded assignments for US patent 12240054 on the USPTO Assignment Center. Therefore, there is no information to suggest a transfer to a shell entity or a known NPE, or any other NPE-related patterns. The patent appears to remain with the original assignee, Trumpf Laser und Systemtechnik GmbH.

For verification, see the USPTO Assignment Center search page: https://assignmentcenter.uspto.gov/

Most Relevant Prior Art for US12240054B2

The analysis of prior art for US Patent 12240054B2 focuses on patents cited by the examiner, indicated by an asterisk (*) in the provided patent document, and those explicitly discussed in the "BACKGROUND" section of US12240054B2.

1. DE3833992C2

• Full Citation: DE3833992C2 - "LIGHT GUIDE AND RADIATION DEVICE", Assignee: Messerschmitt-Boelkow-Blohm Gmbh.
• Publication/Filing Date: Priority Date: 1988-10-06, Publication Date: 1992-03-19.
• Brief Description: This patent describes a method for achieving specific laser beam properties by coupling laser beams from two laser beam sources into a conventional optical fiber at different coupling angles. The resulting beam comprises various wavelengths selected to suit biological or medical processing tasks. The method can also employ a single laser source with a variable wavelength, where coupling conditions into the optical fiber depend significantly on the wavelength.
• Potential Anticipation (35 U.S.C. § 102): DE3833992C2 anticipates the general concept of modifying laser beam properties by coupling into an optical fiber. However, US12240054B2 distinguishes itself by utilizing a multi-clad fiber (specifically, a double-clad fiber) and selectively coupling laser beams into different cores (inner fiber core or outer ring core) to generate varying beam profile characteristics, potentially with a single wavelength. DE3833992C2's reliance on wavelength dependence and a conventional fiber does not disclose the specific multi-clad fiber structure or the selective core coupling mechanism required by independent claims 1 and 11 of US12240054B2. Specifically, claims 1 and 11 explicitly require "a multi-clad fiber having an inner fiber core and at least one outer ring core" and coupling "at least into the inner fiber core" or "at least into at least one outer ring core," which are not present in the teachings of DE3833992C2.

2. US5461692A

• Full Citation: US5461692A - "Multimode optical fiber coupling apparatus and method of transmitting laser radiation using same", Assignee: Amoco Corporation.
• Publication/Filing Date: Priority Date: 1993-11-30, Publication Date: 1995-10-24.
• Brief Description: This patent describes an apparatus and method for efficiently coupling and transmitting high-power laser radiation, particularly from a solid-state laser, through a multimode optical fiber. The invention focuses on matching the laser beam characteristics to the fiber's acceptance characteristics (numerical aperture and core diameter) to achieve efficient coupling and minimize losses. It also includes a lens system for focusing the beam into the fiber, emphasizing long-distance transmission of high-power laser radiation.
• Potential Anticipation (35 U.S.C. § 102): While US5461692A addresses the general coupling of laser radiation into an optical fiber for high-power transmission, it does not disclose the specific structure of a "multi-clad fiber having an inner fiber core and at least one outer ring core." Crucially, it does not teach the elective coupling of a single laser beam or different laser beams/sub-beams into distinct cores (inner vs. outer ring core) of such a multi-clad fiber to generate different beam profile characteristics as explicitly defined in claims 1 and 11 of US12240054B2. Its objective is efficient transmission, not the active manipulation and switching of output beam profiles via selective core engagement in a multi-clad fiber. Therefore, it does not anticipate the key structural and functional elements of claims 1 and 11.

3. JP3645013B2

• Full Citation: JP3645013B2 - "Optical transmission device, solid-state laser device, and laser processing device using them", Assignee: 三菱電機株式会社 (Mitsubishi Denki Kabushiki Kaisha).
• Publication/Filing Date: Priority Date: 1994-10-14, Publication Date: 2005-05-11.
• Brief Description: This patent describes an optical transmission device where a laser beam is introduced into an optical fiber via a condensing lens. The fiber includes a mode conversion optical fiber where light is guided through multiple cores, specifically mentioning a "main core" and a "sub-core (or ring core)". The invention teaches a method to switch between coupling into the main core or both cores to achieve different beam qualities, aiming to maintain beam quality even with a large diameter fiber and reduce fiber end damage.
• Potential Anticipation (35 U.S.C. § 102): JP3645013B2 is highly relevant as it explicitly discloses key elements of US12240054B2. It describes an optical fiber with "multiple cores" including a "main core" and a "sub-core (or ring core)," directly anticipating the "multi-clad fiber having an inner fiber core and at least one outer ring core" of claims 1 and 11. Furthermore, the method to "switch between coupling into the main core or both cores to achieve different beam qualities" strongly anticipates the selective coupling and generation of different beam profile characteristics central to US12240054B2. The primary point of distinction for US12240054B2's independent claims (Claims 1 and 11) might be the explicit requirement for "a first optical fiber configured to guide a first input laser beam to the multi-clad fiber; and a second optical fiber configured to guide a second input laser beam to the multi-clad fiber," and the coupling of these distinct input beams. While JP3645013B2 mentions "a laser beam is introduced," suggesting a single input being switched, it does not explicitly disclose the dual-fiber, dual-input laser beam arrangement.

4. US20060219673A1

• Full Citation: US20060219673A1 - "Apparatus for the industrial processing of a material by optical radiation", Assignee: Spi Lasers Uk Ltd.
• Publication/Filing Date: Priority Date: 2003-12-05, Publication Date: 2006-10-05.
• Brief Description: This patent application describes an apparatus for industrial material processing utilizing optical radiation, particularly a fiber laser. It features a laser source providing a primary beam and a separate auxiliary beam (or beams) that can be directed to a workpiece or into the same delivery fiber as the primary beam. The auxiliary beam can serve purposes like pre-heating, post-heating, or modifying the main beam's effect. It explicitly mentions using different cores of a multi-clad fiber for these different beams, such as the primary beam in a central core and the auxiliary beam in an outer cladding or ring. The intensity distribution of the combined output beam can be varied.
• Potential Anticipation (35 U.S.C. § 102): US20060219673A1 is highly anticipatory of US12240054B2. It describes an apparatus that includes a multi-clad fiber with different cores (e.g., central core, outer cladding/ring) for guiding distinct laser beams ("primary beam" and "auxiliary beam"). This directly anticipates the "multi-clad fiber having an inner fiber core and at least one outer ring core" of claims 1 and 11. Furthermore, the concept of coupling "different input laser beams into the different cores" to modify the combined beam's effect and vary its intensity distribution (and thus beam profile characteristics) aligns closely with the alternative embodiments described in US12240054B2 where "a first laser beam is coupled at least into the inner fiber core... and a different, second laser beam is coupled at least into one outer ring core." The specification also implies the use of two input sources that could be guided by optical fibers. This patent appears to anticipate the fundamental structural and functional aspects of claims 1 and 11, particularly concerning the use of multiple input beams into different cores of a multi-clad fiber to achieve variable output beam characteristics.

The obviousness of US patent 12240054 under 35 U.S.C. § 103 can be argued by combining the teachings of prior art references. The core innovation of US12240054 lies in using a multi-clad fiber with an inner fiber core and at least one outer ring core, and selectively coupling a laser beam (or different laser beams) into these distinct regions to generate different output beam profile characteristics for various applications.

Independent Claims of US12240054:

Claim 1 (System): A system comprising a multi-clad fiber (with an inner fiber core and at least one outer ring core), a first optical fiber guiding a first input laser beam, and a second optical fiber guiding a second input laser beam to the multi-clad fiber. The system is configured to couple at least one of: the first input laser beam at least into the inner fiber core, or the second input laser beam at least into the at least one outer ring core of the multi-clad fiber.

Claim 11 (Method): A method comprising guiding a first input laser beam by a first optical fiber and a second input laser beam by a second optical fiber to a fiber end of a multi-clad fiber (with an inner fiber core and at least one outer ring core). The method includes coupling these laser beams into the fiber end, where at least one of the following occurs: the first input laser beam is coupled at least into the inner fiber core, or the second input laser beam is coupled at least into the at least one outer ring core. An output laser beam is generated, whose beam profile characteristic differs depending upon the coupling.

Prior Art Combination for Obviousness:

A strong argument for obviousness can be made by combining US20020071647A1 (Manzur) with DE 38 33 992 A1 (Messerschmitt-Boelkow-Blohm).

1. US20020071647A1 (Manzur) - Multi-clad Fiber Structure:
   The title of US20020071647A1, "Multi-clad optical fiber and amplifier," strongly suggests the disclosure of a multi-clad optical fiber. In the field of laser technology and fiber optics, a "multi-clad fiber," especially a "double-clad fiber" as frequently referenced in US12240054, commonly refers to a fiber structure comprising an inner fiber core and at least one outer ring core, surrounded by different cladding layers. This reference would thus teach the fundamental multi-clad fiber structure required by claims 1 and 11. The "amplifier" aspect further indicates its relevance to laser applications, often involving high power.

2. DE 38 33 992 A1 (Messerschmitt-Boelkow-Blohm) - Varying Coupling for Different Beam Properties:
   As described in the background of US12240054, DE 38 33 992 A1 "describes a method for achieving specific laser beam properties in which the laser beams of two laser beam sources are coupled into a conventional optical fiber at different coupling angles." This prior art teaches the general concept of varying coupling conditions into an optical fiber to modify the output laser beam's characteristics. While DE 38 33 992 A1 uses a "conventional optical fiber" and its beam formation is "dependent on the wavelength," it clearly establishes the principle of manipulating input coupling to alter output beam properties.

Motivation to Combine:

A person having ordinary skill in the art (PHOSITA) in 2010 (the priority date of US12240054) would have been motivated to combine the teachings of Manzur and DE 38 33 992 A1 for the following reasons:

• Addressing Known Limitations: US12240054 explicitly states that the method of DE 38 33 992 A1 "proves not to be optimum on account of its disproportionate complexity for such cases and its limiting specialization in applications of a different type" and is "limited to the beam formation dependent on the wavelength." A PHOSITA, seeking to overcome these limitations and achieve more versatile, application-specific beam profile changes, would naturally look to more advanced fiber structures beyond the "conventional optical fiber" of DE 38 33 992 A1.
• Leveraging Inherent Fiber Properties: Manzur's disclosure of a multi-clad optical fiber would immediately suggest to a PHOSITA that such a fiber inherently provides multiple distinct light-guiding paths (e.g., the inner core and the outer ring core). Knowing from DE 38 33 992 A1 that modifying coupling conditions into any fiber can alter output beam properties, it would be an obvious design choice to extend this principle to a multi-clad fiber by selectively coupling laser beams into its distinct inner core or outer ring core. This directly exploits the structural advantage of a multi-clad fiber.
• Achieving Desired Beam Profiles for Material Processing: The patent itself highlights the desire for different beam qualities in material processing, such as a "comparatively good beam quality with a sharp focus... for a laser cutting process, and, in contrast, a ‘reduced’ beam quality with a ‘blurred’ focus... particularly suitable for welding processes." A PHOSITA would recognize that coupling into a smaller inner core typically yields a higher beam quality and sharper focus, while coupling into a larger outer ring core (or both regions) can produce a wider, potentially more uniform beam profile. The motivation to achieve these well-known different beam characteristics for different laser processing tasks would drive the selective coupling into the different cores of a multi-clad fiber.
• Routine Design Choice for Multiple Sources: DE 38 33 992 A1 already describes coupling "laser beams of two laser beam sources" into a fiber. If a multi-clad fiber (Manzur) is known to have distinct guiding regions, it would be a routine design choice to guide these multiple laser beams (or sub-beams) via separate input optical fibers and selectively couple them into the corresponding core regions of the multi-clad fiber. This provides precise control over the power distribution and resulting beam profile, addressing the explicit objective of US12240054 to allow "an application-specific change to the laser beam characteristics with relatively little effort."

Therefore, a PHOSITA, motivated to overcome the limitations of prior art like DE 38 33 992 A1 and leverage the known structural advantages of multi-clad fibers (Manzur) to achieve versatile laser beam profiles for various applications, would have found it obvious to combine these references to arrive at the systems and methods claimed in US12240054. The selective coupling into different core regions of a multi-clad fiber to produce varying beam profiles is a logical and predictable outcome of such a combination, meeting the functional requirements articulated in the patent.