Fiber cooling

Abstract

A cooling system transversely (meaning perpendicular to a fiber draw direction) directs fluid (e.g., air, helium (He), or other gases) toward an optical fiber from multiple directions during draw. The system controls fiber position by controlling both fluid flow rates and fluid flow directions so that the net effect of the fluid is zero on fiber position. The cooling system comprises stacks that are movable toward each other (e.g., to close) or away from each other (e.g., to open) during draw. By providing multiple stacks that open and close, the system permits practical integration into currently existing optical fiber draw towers, while concurrently providing greater than five times (>5x) efficiency compared to ambient environments.

Description

FIBER COOLINGCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional patent application serial number 63 / 748,585, filed 2025-January-23, with first-named inventor Jeschke, and having the title "Advanced Fiber Cooling Device," which is incorporated herein by reference in its entirety.BACKGROUND FIELD OF THE DISCLOSURE

[0002] The present disclosure relates generally to optical fibers and, more particularly, to systems and methods for cooling optical fibers.DESCRIPTION OF RELATED ART

[0003] Optical fiber draw towers are well known to those having ordinary skill in the art. A faster fiber draw speed will produce more optical fiber in the same amount of time than a slower fiber draw speed.SUMMARY

[0004] The present disclosure provides systems and methods for cooling optical fibers during optical fiber draw. One embodiment is cooling system comprising a longitudinal (z) axis (defined by a direction of optical fiber draw) and a transverse (xy) plane that is perpendicular to the z-axis. The xy -plane comprises a flow (x) axis that is substantially parallel to a fluid flow direction and a normal-to-flow (y) axis that is perpendicular to the x-axis. The center (x=0; y=0) of the xy-plane is coextensive with a position of the optical fiber during the optical fiber draw.

[0005] The cooling system comprises a first stack that is movable along the x-axis between a first x-axis location (x=-xl) and a second x-axis location (x=-x2). The cooling system comprises a second stack that is also movable along the x-axis between a third x-axis location (x=+x2) and a fourth x-axis location (x=+xl). In other words, the first stack and the second stack are movable toward each other or away from each other. For someembodiments, the system comprises a rail that is operatively coupled to the stacks for guiding the movement of the stacks along the rail.

[0006] Both the first stack and the second comprise sets of one or more blocks. Each block has a block length (measured from a block back to a block front), a block height (measured from a block top to a block bottom), and a block width (measured from a block left side to a block right side).

[0007] Each block further comprises a fluid channel that extends from the block back to the first predefined position between the block front and the block back. The fluid channel allows for the introduction of a fluid (e.g., gas, such as air, helium (He), etc.) from the block back to the predefined position. To be clear, the predefined position is not the actual position of the optical fiber travel path but, rather, the actual position of where the fluid channel ends (and, as shown below, where a notch in the block begins).

[0008] Each block also comprises a notch that extends from the block front to the predefined position. It is within this notch that the optical fiber resides during optical fiber draw. Again, the predefined position is not the optical fiber travel path; a location slightly beyond the predefined position and within the notch is the actual travel path of the optical fiber. The notch exhibits mirror symmetry about the xz-plane. The notch has a length that is shorter than the block length (as the notch only extends as far back as the first predefined position). The height of the notch is coextensive with the block height, but the width of the notch is less than the first block width. The notches exhibit an outward taper from the fluid channels of approximately 1.5 degrees (-1.5°) half angle (or a total of ~3° full angle) to ~5° half angle (or a total of -10° full angle), meaning, the notches start narrow at the fluid channels and become broader toward the front ends of the blocks. For some embodiments, the notch exhibits a two-stage taper, starting with a narrow -1.5° half angle in a first stage and, thereafter, becoming a broader half angle (e.g., -45° or less) in a second stage. In yet other embodiments, the notch exhibits a nonlinear taper, starting with -1.5° half angle and progressively increasing a broader angle (e.g., -45° or less). To be clear, it is within this tapered zone that the optical fiber travel path resides.

[0009] Both the first stack and the second stack comprise sets of spaces, which are interleaved with their corresponding sets of blocks. The interleaving of the blocks with spaces on the first stack produces an interlacing structure on the first stack. The interleavingof the blocks with the spaces on the second stack produces an interlacing structure on the second stack, which structurally couples to the interlacing structures on the first stack as the stacks move toward each other. In other words, the first stack and the second stack structurally couple together via their respective interlacing structures as the stacks move toward each other.

[0010] For some embodiments, the space is simply an empty space (or a gap), meaning, the blocks are simply spaced apart from each other. The space has a back that is coextensive with the block back, a front that is coextensive with the predefined position (where the notch terminates), and a width that is coextensive with the block width. Because the spaces are interleaved with the blocks, a space top is located adjacent to a corresponding block bottom, while a space bottom is located adjacent to a corresponding block top.Because the interlacing structures on one stack are configured to structurally couple (or mate) with the interlacing structures on another stack, the space height on one stack corresponds to (but is slightly larger than) the block height on the other structure, thereby permitting structural coupling but without actually physically touching each other. The interlacing structures are similar to how interlacing fingers connect two (2) hands together, with a primary difference being that the interlacing structures do not physically make contact with opposing interlacing structures, but fingers on one hand do make physical contact with interlaced fingers of an opposing hand.

[0011] It is worth observing that the spaces on one stack provide an exit for fluid that is introduced from an opposing stack. In other words, if a first stack and a second stack are configured opposite to each other, then the fluid that is introduced from the notches in the blocks in the first stack will exit through the spaces in the second stack. Similarly, the fluid that is introduced from the notches in the blocks in the second stack will exit through the spaces in the first stack. Ultimately, the spaces provide an unobstructed path for the fluid to exit, thereby reducing the possibility of exiting air affecting the optical fiber. Having open spaces (rather than a defined channel for the fluid to exit) provides advantages (e.g., fewer components, less obstructive path, etc.).

[0012] Continuing, the system further comprises a path for drawing an optical fiber (meaning, the optical fiber path during optical fiber draw). The path is substantially centered longitudinally between the first stack and the second stack. In some embodiments, thesystem comprises a monitoring system (e.g., camera, lasers, etc.) for capturing the movement of the optical fiber during the optical fiber draw (thereby permitting the system to monitor the behavior or movement of the optical fiber during draw).

[0013] The disclosed cooling system achieves a cooling efficiency that is greater than five times (>5x) the cooling efficiency achievable in an ambient environment (meaning, without a cooling system). For some embodiments up to 35x cooling is achievable.

[0014] Broadly speaking, another embodiment is a system comprising stacks that are selectively movable toward each other or away from each other in a fluid flow direction (arbitrarily designated as being along ±x axis, which is perpendicular to an optical fiber draw direction, designated as z-axis). The system includes a path for drawing an optical fiber, with the path being located between the stacks and extending in the z-direction. Each stack comprises its own set of interlacing structures, with the interlacing structures being configured to structurally couple together the stacks (without actually touching each other). Each stack also has a set of fluid channels for introducing a fluid into the path at its own fluid flow rate and in its own fluid flow direction. Introduction of the fluid (e.g., air, helium (He), or other gas) along each of the fluid flow directions and at each of the fluid flow rates produces a physical impact on the optical fiber during draw (as the fluid contacts the optical fiber). However, the net effect of the combination of the respective flow directions and respective fluid flow rates is a cancellation (or counteracting) of the physical impact on fiber path For example, the fluid introduced from the first stack counteracts the fluid introduced from the second stack, etc. For some embodiments, the stacks are movable independent of each other, while for other embodiments, the stacks move together in a coordinated fashion.

[0015] For some embodiments of the broader system, the stacks comprise blocks interleaved with spaces. This interleaved structure produces interlacing structures that permit one stack to structurally couple to another stack. The fluid channels are tapered outwardly. The broad embodiment also achieves cooling efficiencies between 5x and 35x, as compared to an ambient environment.

[0016] Another broad embodiment is a cooling system that transversely channels fluid (e.g., air, helium (He), or other gases) toward an optical fiber from multiple directions during draw. The system controls fiber position by controlling both fluid flow rates and fluid flow directions so that the net effect of the fluid is zero. The cooling system comprisesstacks that are movable toward each other (e.g., to close) or away from each other (e.g., to open) during draw. By providing multiple stacks that open and close, the system permits practical integration into currently existing optical fiber draw towers, while concurrently providing greater than five times (>5x) efficiency compared to ambient environments.

[0017] Other systems, devices, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure.Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

[0019] FIG. 1 is a diagram showing a perspective view of a portion of a cooling system 100 with two (2) structurally coupled stacks, namely, a first stack 102 and a second stack 152.

[0020] FIG. 2 is a diagram showing a perspective view of the components for the first stack 102 from FIG. 1.

[0021] FIG 3. is a diagram showing a perspective view of the components for the second stack 152 from FIG. 1.

[0022] FIG. 4 is a diagram showing a front view of the cooling system 100, demonstrating structural coupling of interlacing structures 842, 942.

[0023] FIG. 5 is a diagram showing an enlarged front view of a top of the cooling system 100 showing the interlacing structures 842, 942 of FIG. 4 in greater detail, along with a rail 402 for guiding the first stack 102 and the second stack 152.

[0024] FIG. 6 is a diagram showing an enlarged view of the interlacing structures 842, 942 of FIG. 5 in greater detail.

[0025] FIG. 7 is a diagram showing a perspective view of the portion of the system100 shown in FIG. 6.

[0026] FIG. 8 is a diagram showing a top view of one embodiment of a block 202, 302 from FIGS. 1 through 7.

[0027] FIG. 9 is a diagram showing an enlarged view of a notch 262, 362 that provides a path 602 of an optical fiber during draw.

[0028] FIG. 10 is a diagram showing an embodiment of a monitoring system 1002, which permits monitoring of a positional behavior of an optical fiber during draw.DETAILED DESCRIPTION OF THE EMBODIMENTS

[0029] Optical fiber draw speed is limited by a height (or length if the fiber is drawn horizontally) of a draw tower because optical fibers must cool sufficiently to protect the surface of the optical fiber before mechanical contact, such as applying a protective coating. Generally, optical fibers are cooled to less than one-hundred-and-fifty degrees Celsius (<150°C) before coatings are applied. To increase draw speeds, cooling devices are sometimes installed on optical fiber draw towers. Conventional cooling devices are tubular structures that use axial flow along the fiber draw direction (z-axis). Due to its low molecular weight and relative inertness, helium (He) is the most effective and safe gas for cooling. However, He is expensive and limited in supply.

[0030] Optical fibers can also be cooled by transverse gas flow (along the xy -plane, rather than along the z-axis). As one can appreciate, transverse gas flows become more efficient as the fluid source is placed closer to the fiber. However, close proximity of gas jets will correspondingly increase vibration or other flow-related physical effects on the optical fiber. In addition to proximity, cooling efficiency is proportional to the fluid flow rate. Although higher flow rates increase cooling efficiency, the higher flow rates also increase vibrations that lead to optical fibers making physical contact with nearby surfaces (or other detrimental effects on the optical fiber). Excessive vibration and excessive motion of the fiber can also, in very bad cases, physically damage or even break an optical fiber during draw (by, for example, forcing the optical fiber to make contact with nearby surfaces).

[0031] To mitigate for these and other problems, this disclosure teaches a cooling system with transverse channels that direct fluid (e.g., air, helium (He), or other gases) toward an optical fiber from multiple directions during draw. The system controls fiberposition by controlling both fluid flow rates and fluid flow directions so that the net effect of the fluid on the optical fiber position is zero (or as close to zero as possible). The cooling system comprises stacks that are movable toward each other (e.g., closing the system) or away from each other (e.g., opening the system) during draw. By providing multiple stacks that open and close, the system permits practical integration into currently existing optical fiber draw towers, while concurrently providing greater than five times (>5x) efficiency compared to ambient environments.

[0032] Having provided a broad technical solution to a technical problem, reference is now made in detail to the description of the embodiments as illustrated in the drawings. While several embodiments are described in connection with these drawings, there is no intent to limit the disclosure to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents. Insofar as different aspects of a preferred embodiment of a cooling system are shown in FIG. 1 through FIG. 10, the drawings are discussed together for clarity (rather than discussing each figure separately). To the extent necessary to clearly explain the structure and operation of various aspects of the cooling system, each individual figure is sometimes referenced along with its corresponding features.

[0033] FIGS. 1 through 10 show an embodiment of a cooling system 100. For clarity, FIGS. 1 through 10 show a longitudinal axis (or z-axis) as defining a direction of optical fiber draw and a transverse plane (or xy -plane) that is perpendicular to the z-axis. Arbitrarily, the x-axis in the xy-plane is designated as a flow axis (as the x-axis will be substantially parallel to a fluid flow direction) and the y-axis in the xy-plane is designated as a normal -to-flow axis. Insofar as an optical fiber will be positioned within the system 100 during draw, the center of the xy-plane (x=0, y=0) is designated to be coextensive with the location of the optical fiber during the optical fiber draw.

[0034] With this in mind, as shown in FIG. 1, the cooling system 100 generally comprises a first stack 102 and a second stack 152 that is structurally coupled to the first stack 102. The first stack 102 is movable along the x-axis between a first x-axis location (designated as x=-xl) and a second x-axis location (designated as x=-x2). The first stack 102 comprises a first set of blocks 202a . . . 202n (individually and collectively abbreviated as 202). For later reference, each of the first set of blocks 202 has a first block length 208,which is measured as a distance between the first block back 204 and the first block front 206. Each first block 202 also has a first block width 218a, which is measured between the first block left side 214 (at a block left position (+y 1)) and the first block right side 216 (at a block right position (-yl)). Each first block 202 further comprises a first block height 228, which is measured between the first block top 224 and the first block bottom 226.

[0035] Each first block 202 also has a first notch 262 that extends from the first block front 206 to a first predefined position 234 between the first block front 206 and the first block back 204. To be clear, the predefined position 234 is not the optical fiber travel path itself; the predefined position 234 merely defines where one end of the notch 262 (with the travel path of the optical fiber being somewhere within the notch 262, as explained later). The first notch 262 exhibits planar symmetry (or mirror symmetry) about an xz-plane, meaning that it is left-right symmetric. Because the first notch 262 extends only to the predefined position 234 (along the x-direction), the first notch 262 has a first notch length 802 that is shorter than the first block length 208. The first notch 262 is shown in greater detail in FIGS. 8 and 9. Insofar as the first notch 262 in preferred embodiments is a cutout or a gap in the first block 202, the first notch 262 has a first notch height 248 that is coextensive with the first block height 228 and, also, a first notch width 818 that is less than the first block width 218a.

[0036] The first notch 262, as shown in the embodiment of FIGS. 8 and 9, has a two-stage taper with a narrower taper beginning at the predefined position 234 and a broader taper ending at the first block front 206. In some embodiments, the narrower taper has a half angle of approximately 1.5 degrees (-1.5°) (meaning, -1.5° on each side of the xz-plane of symmetry) or a full angle of ~3°, while the broader taper has a half angle of -45° (or less). In other embodiments the narrow taper can be as large as ~5° half angle (or -10° full angle). In other embodiments, the first notch 262 exhibits a linear taper (e.g., -1.5° half angle for entire taper), while yet other embodiments include a first notch 262 that exhibits a non-linear taper (e.g., -1.5° half angle at the predefined position and progressively increasing to -45° half angle at the first block front 206. It is within this tapered notch 262 that the optical fiber travel path resides.

[0037] The first block 202 also includes a first fluid channel 822 that extends from the first block back 204 to the first predefined position 234. The first fluid channel 822introduces a fluid (e g., air, Helium, or other gas for cooling) from the first block back 204 to the first notch 262. As noted earlier, the optical fiber will be located in this notch 262 and, therefore, the introduced fluid will act as a cooling agent for the optical fiber during draw.

[0038] In addition to the first set of blocks 202, the first stack 102 also comprises a first set of spaces 232a . . . 232m (individually and collectively abbreviated as 232). The first spaces 232 are interleaved with the first blocks 202.

[0039] Because the first spaces 232 separate the first blocks 202, each first space 232 has a first space back 804 that is coextensive with the first block back 204. Also, because it is preferable to avoid interference in the area that is defined by the notch 262, each first space 232 has a first space front 834 that is coextensive with the first predefined position 234 (which is the terminal end of the notch 262). The first space 232 has a first space width 218b that is coextensive with the first block width 218a. Because the first spaces 232 are interleaved with the first blocks 202, the first space top 244 is located adjacent to a corresponding first block bottom 226, and a first space bottom 246 is located adjacent to a corresponding first block top 224. Each first space 232 has a first space height 238 that is measured between the first space top 244 and the first space bottom 246. The significance of the first space height 238 will become clearer during the detailed discussion of the second stack 152, below. Ultimately, a first set of interlacing structures 842 (as shown in greater detail in FIGS. 4, 5, 6, and 7) is formed by the first set of blocks 202 being interleaved with the first set of spaces 232.

[0040] In addition to the first stack 102, the cooling system 100 comprises a second stack 152 that is also movable along the x-axis (between a third x-axis location (designated as x=+x2) and a fourth x-axis location (designated as x=+xl). The second stack 152 comprises a second set of blocks 302a . . . 302n (or, in some cases, 302(n+l) so that there is one (1) more block in the first set of blocks 202 than there is in the second set of blocks 302). For simplicity of labeling, the blocks 302a . . . 302n are individually and collectively abbreviated as 302. For later reference, each of the second set of blocks 302 has second block length 308 (as measured along the x-direction between a second block back 304 and a second block front 306). Each second block 302 also has a second block width 318a (as measured between a second block left side 314 corresponding to the first block right side at -yl and a second block right side 316 corresponding to the first block left side at +yl,thereby making the second block width 318a coextensive with the first block width 218a). Each second block 302 further comprises a second block height 328 (as measured between a second block top 324, which corresponds to a top of one of the first spaces 244, and a second block bottom 326, which corresponds to a bottom of the one of the first spaces 246). The relationship between the second blocks 302 and the first spaces 232 permits structural coupling (e.g., interlacing) of the first stack 102 with the second stack 152. In other words, a block height 328 of a block 302 on the second stack 152 would be approximately the same but slightly smaller than the space height 238 of a corresponding space 232 on the first stack 102. Thus, although the structures would interlace, the block height 328 would not coextensively be the same height as the space height 238.

[0041] Each second block 302 has a second notch 362, similar to how the first block 202 had a first notch 262. The second notch 362 extends from the second block front 306 to a second predefined position 334, which is between the second block front 306 and the second block back 304. The second notch 362 exhibits planar symmetry (or mirror symmetry) about the xz-plane. The second notch 362 has a second notch length 902 (measured along the x-direction, as shown in FIGS. 8 and 9), with the second notch length 902 being shorter than the second block length 308. The second notch 362 has a second notch height 348 that is coextensive with the second block height 328 and, also, a second notch width 918 that is less than the second block width 318a.

[0042] Each second block 302 comprises a second fluid channel 922 (as shown in FIGS. 8 and 9), which extends from the second block back 304 to the second predefined position 334, with the second fluid channel 922 being configured to introduce a fluid (e.g., He, air, etc.) from the second block back 304 to the second notch 362 (where the optical fiber will reside during draw).

[0043] Functionally, the fluid channels 822, 922 create laminar flow of fluid into the notches 262, 362, which impacts the fiber. The flow of fluid produces forced convective cooling, which yields higher cooling efficiency. The efficiency is proportional to fluid speed. To optimize cost (or optimize use of the fluid), the dimensions of the space in which the fiber eventually resides (as measured perpendicular to the longitudinal axis of the fiber) is approximately the same order of magnitude as the fiber diameter. Optimally, the space should be as small as possible but large enough to avoid physical contact between the opticalfiber and the blocks 202, 302. In preferred embodiments, the fluid channels 822, 922 are approximately 100 micrometers (~ 100pm) wide (y-direction), approximately two millimeters (~2mm) long (x-direction), and slightly less than the block height 228, 328 (z-direction). Cooling efficiency increases with the height of the fluid in the fluid channels 822, 922.

[0044] The second stack 152 comprises a second set of spaces 332a . . . 332m (individually and collectively abbreviated as 332) interleaved with the second set of blocks 302. Each second space 332 comprises a second space back 904 (as shown in FIGS. 8 and 9) that is coextensive with the second block back 304, a second space front 934 that is coextensive with the second predefined position 334, and a second space width 318b that is coextensive with the second block width 318a.

[0045] Positionally, a second space top 344 is located adjacent to a corresponding second block bottom 326, a second space bottom 346 located adjacent to a corresponding second block top 324, and a second space height 338 is measured between the second space top 344 and the second space bottom 346. For purposes of structurally coupling together the first stack 102 and the second stack 152, the second space height 338 corresponds to (but is not exactly coextensive with) the first block height 228. Consequently, the second stack 152 comprises a second set of interlacing structures 942 (as shown in greater detail in FIGS. 4, 5, 6, and 7) formed by the second set of blocks 302 being interleaved with the second set of spaces 332, with the second set of interlacing structures 942 being configured to structurally couple (e g., interlace) with the first set of interlacing structures 842 as the first stack 102 moves toward the second stack 152 (respectively to -xl and +xl).

[0046] As shown in FIGS. 6 and 7, the system 100 comprises a fiber path (602) through which the optical fiber travels during draw. The fiber path 602 is substantially centered (longitudinally) between the first stack 102 and the second stack 152. More precisely, the fiber path 602 is located in the spaces formed between the notches 232, 332 of the blocks 202, 302. For some embodiments, the notches 262, 362 include tapers 852, 952. Specifically, the tapers 852, 952 have a narrower notch width 818, 918 toward the predefined positions 234, 334 (where the channels 822, 922 introduce the fluid into their respective notches 262, 362) and a larger separation (862, 962) toward the block fronts 206, 306.

[0047] For some embodiments, the system 100 comprises a rail 402 (as shown in FIGS. 4 and 5), which is operatively coupled to both the first stack 102 and the second stack152, thereby permitting the rail 402 to guide the movements of the first stack 102 and the second stack 152 as the stacks 102, 152 travel along the x-direction (e.g., between ±xl and ±x2). For other embodiments, the system 100 comprises a monitoring system 1002 (e.g., camera, lasers, etc.). The monitoring system 1002 captures positional movement of the optical fiber as the optical fiber is drawn, thereby permitting the system 100 to either move the stacks 102, 152 closer together or move the stacks 102, 152 farther apart to properly maintain equilibrium at the location of the optical fiber. Alternatively, the monitoring of the optical fiber position during draw also permits the system 100 to adjust the fluid flow to properly maintain positional equilibrium of the optical fiber. Thus, for example, as speed, preform position in the furnace, unwanted cross-flow of air, etc. alter the position of the optical fiber from its desired path, the monitoring system (e.g., camera, laser, etc.) permits re-centering of the optical fiber on its path during draw.

[0048] The disclosed cooling system 100 has a general cooling efficiency that is greater than five times (>5x) the cooling efficiency of an ambient environment. When properly configured, the disclosed cooling system 100 can have a cooling efficiency that can be as high as 35x ambient cooling efficiency.

[0049] In its broadest embodiment, the system 100 comprises a first stack 102 that is selectively movable in a fluid flow direction (±x) (the fluid flow direction (±x) being perpendicular to an optical fiber draw direction (z)) and a second stack 152 that is also selectively movable in the fluid flow direction (±x). In other words, the first stack 102 and the second stack 152 are selectively movable toward each other or away from each other. For some embodiments, the respective movements can be independent of each other, while for other embodiments, the respective movements can be coordinated movements. The system 100 further comprises a fiber path 602 for drawing an optical fiber (along the z-axis and between the first stack 102 and the second stack 152. The system comprises a first set of interlacing structures 842 located on the first stack 102 and a second set of interlacing structures 942 located on the second stack 152. These interlacing structures 842, 942 permit structural coupling (e.g., interlacing, etc.) of the first stack 102 with the second stack 152 as they move toward each other. The stacks 102, 152 have fluid channels 822, 922, which are located in their respective stacks 102, 152. The first set of fluid channels 822 introduces a first fluid into the fiber path 602 in a first fluid flow direction that is transverse (x-direction)to the optical fiber draw direction (z-di recti on). The first fluid is introduced at a first fluid flow rate. The first fluid flow rate and the first fluid flow direction produces a first physical impact on the optical fiber xy position during the optical fiber draw (due to vibrations or other fluid effects (e.g., turbulence, drag, differential pressure, etc.)). The second set of fluid channels 922 introduces a second fluid into the fiber path 602. The second fluid is introduced in a second fluid flow direction at a second fluid flow rate. The second fluid flow rate and the second fluid flow direction produces a second physical impact on the optical fiber xy position during the optical fiber draw. The second physical impact substantially counteracts the first physical impact, thereby maintaining the optical fiber at substantially the center (x=0, y=0) of the fiber path 602 and minimizing vibrational (or other physical) impacts on the optical fiber during draw.

[0050] Although preferred embodiments of the system 100 have been discussed with reference to FIGS. 1 through 10, it should be appreciated that certain variations or details can be implemented to improve system functionality. For example, the total number of blocks used in both stacks 102, 152, combined, is an odd number in some embodiments, thereby configuring a starting block and an ending block to provide fluid in the same direction. This same-direction beginning and ending block (or odd-block configuration) mitigates for venturi effects that arise at the end block (or last block in the fiber travel path). Of course, an evenblock configuration can also be used by providing a special entrance block (not shown) and a special exit block (not shown) that accounts for fiber line deviations at the entrance and at the exit.

[0051] Moreover, although two (2) counter-posing, linearly arranged stacks 102, 152 are shown to illustrate the operation of the system 100, it should be appreciated that the stacks 102, 152 need not be linear, as long as the combined flow of fluids produces a net zero impact on the optical fiber position. As such, for some embodiments, the two stacks 102, 152 can be arranged as a double helix (similar to strands of deoxyribonucleic acid (DNA)).

[0052] Consequently, unlike conventional systems, the disclosed two-stack system 100 has the ability to transversely direct fluids (e.g., air, helium (He), or other gases) toward an optical fiber from multiple directions during draw by controlling both fluid flow rates and fluid flow directions so that the net effect is zero on fiber position. Further control is possible by moving the sources of the fluids (e.g., stacks) toward each other (e.g., to close the system)or away from each other (e.g., to open the system) during draw. The controllability of the net effect allows the system to maintain the optical fiber at substantially the center of the optical fiber path during draw. Also, by providing multiple stacks that open and close, the system permits practical integration into currently existing optical fiber draw towers, while concurrently providing greater than five times (>5x) efficiency compared to ambient environments and, sometimes, up to35x efficiency.

[0053] Although exemplary embodiments have been shown and described, it will be clear to those of ordinary skill in the art that a number of changes, modifications, or alterations to the disclosure as described may be made. All such changes, modifications, and alterations should therefore be seen as within the scope of the disclosure.

Claims

What is claimed is:

1. A cooling system (100) comprising:(a) a longitudinal (z) axis defined by a direction of optical fiber draw;(b) a transverse (xy) plane perpendicular to the z-axis, the xy-plane comprising:(bl) a flow (x) axis that is substantially parallel to a fluid flow direction;(b2) a normal-to-flow (y) axis that is perpendicular to the x-axis; and(b3) a center (x=0; y=0) of the xy-plane, the center being coextensive with a position of the optical fiber during the optical fiber draw;(c) a first stack (102) movable along the x-axis between a first x-axis location (x=-xl) and a second x-axis location (x=-x2), the first stack (102) comprising:(cl) a first set of blocks (202a . . . 202n), each of the first set of blocks (202a . . .202n) comprising:(cl A) a first block back (204);(clB) a first block front (206);(clC) a first block length (208) measured along the x-axis from the first block back (204) to the first block front (206);(clD) a first block left side (214) at a block left position (+y 1);(clE) a first block right side (216) at a block right position (-y 1);(clF) a first block width (218a) measured along the y-axis from +yl to -yl; (clG) a first block top (224);(clH) a first block bottom (226);(cl I) a first block height (228) measured along the z-axis from the first block top (224) to the first block bottom (226);(cl J) a first notch (262) extending from the first block front (206) to a first predefined position (234) between the first block front (206) and the first block back (204), the first notch (262) exhibiting planar symmetry about an xz-plane, the first notch (262) comprising:(cl JI) a first notch center at y=0 in the xz-plane;(clJ2) a first notch length (802), the first notch length (802) being shorter than the first block length (208), the first notch length (802) being measured along thex-direction from the first block front (206) to the first predefined position (234);(clJ3) a first notch height (248) coextensive with the first block height (228); and(clJ4) a first notch width (818) that is less than the first block width (218a); (clK) a first fluid channel (822) extending from the first block back (204) to the first predefined position (234), the first fluid channel (822) for introducing a fluid from the first block back (204) to the first notch (262);(c2) a first set of spaces (232a . . . 232m) interleaved with the first set of blocks (202a . . . 202n), each of the first set of spaces (232a . . . 232m) comprising:(cl A) a first space back (804) coextensive with the first block back (204);(clB) a first space front (834) coextensive with the first predefined position (234);(clC) a first space width (218b) coextensive with the first block width (218a); and(clD) a first space top (244) located adjacent to a corresponding first block bottom (226);(clE) a first space bottom (246) located adjacent to a corresponding first block top (224); and(clF) a first space height (238) measured between the first space top (244) and the first space bottom (246);(c3) a first set of interlacing structures (842) formed by the first set of blocks (202a . . . 202n) being interleaved with the first set of spaces (232a . . . 232m); and(d) a second stack (152) movable along the x-axis between a third x-axis location (x=+x2) and a fourth x-axis location (x=+xl), the second stack (152) comprising:(d l) a second set of blocks (302a . . . 302n), each of the second set of blocks (302a . . . 302n) comprising:(dlA) a second block back (304);(dlB) a second block front (306);(dlC) a second block length (308) measured along the x-axis from the second block back (304) to the second block front (306);(dlD) a second block left side (314) corresponding to the first block right sideat -yl;(dlE) a second block right side (316) corresponding to the first block left side at +yi;(dlF) a second block width (318a) coextensive with the first block width (218a); (dlG) a second block top (324) corresponding to a top of one of the first spaces (244);(dlH) a second block bottom (326) corresponding to a bottom of the one of the first spaces (246);(dll) a second block height (328) measured along the z-axis from the second block top (324) to the second block bottom (326), the second block height (328) corresponding to the first space height (238);(dl J) a second notch (362) extending from the second block front (306) to a second predefined position (334) between the second block front (306) and the second block back (304), the second notch (362) exhibiting planar symmetry about the xz-plane, the second notch (362) comprising:(dl JI) a second notch center at y=0 in the xz-plane;(d 1 J2) a second notch length (902), the second notch length (902) being shorter than the second block length (308), the second notch length (902) being measured along the x-direction from the second block front (306) to the second predefined position (334);(d 1 J3) a second notch height (348) coextensive with the second block height (328); and(dl J4) a second notch width (918) that is less than the second block width (318a);(dlK) a second fluid channel (922) extending from the second block back (304) to the second predefined position (334), the second fluid channel (922) for introducing a fluid from the second block back (304) to the second notch (362);(d2) a second set of spaces (332a . . . 332m) interleaved with the second set of blocks (302a . . . 302n), each of the second set of spaces (332a . . . 332m) comprising:(dlA) a second space back (904) coextensive with the second block back (304); (dlB) a second space front (934) coextensive with the second predefinedposition (334);(dlC) a second space width (318b) coextensive with the second block width (318a); and(dlD) a second space top (344) located adjacent to a corresponding second block bottom (326);(dlE) a second space bottom (346) located adjacent to a corresponding second block top (324); and(dlF) a second space height (338) measured between the second space top (344) and the second space bottom (346), the second space height (338) corresponding to the first block height (228); and(d3) a second set of interlacing structures (942) formed by the second set of blocks (302a . . . 302n) being interleaved with the second set of spaces (332a . . . 332m), the second set of interlacing structures (942) for structurally coupling with the first set of interlacing structures (842) as the first stack (102) moves toward -xl and the second stack (152) moves toward +xl; and(e) a path (602) for drawing an optical fiber, the path (602) being substantially centered longitudinally between the first stack (102) and the second stack (152).

2. The cooling system (100) of claim 1, wherein:the first notch (262) comprises:(cl J5) a first taper (852) comprising:(clJ5a) the first notch width (818) at the first predefined position (234); and (cl J5b) a first separation (862) at the first block front (206), the first separation (862) being larger than the first notch width (818); andthe second notch (362) comprises:(dl J5) a second taper (952) comprising:(dlJ5a) the second notch width (918) at the second predefined position (334); and(dl J5b) a second separation (962) at the second block front (306), the second separation (962) being larger than the second notch width (918).

3. The cooling system (100) of claim 1, wherein the fluid is a gas.

4. The cooling system (100) of claim 3, wherein the fluid is air.

5. The cooling system (100) of claim 1, further comprising a rail (402) operatively coupled to the first stack (102), the rail (402) being operatively coupled to the second stack (152), the rail (402) for guiding movement of the first stack (102) between -x2 and -xl, the rail (402) for guiding movement of the second stack (152) between +xl and +x2.

6. The cooling system (100) of claim 1, further comprising a monitoring system (1002) for capturing movement of the optical fiber as the optical fiber is drawn.

7. The cooling system (100) of claim 1, further comprising a cooling efficiency that is greater than five times (>5x) a cooling efficiency of an ambient environment.

8. A system (100) comprising:a first stack (102) selectively movable in a fluid flow direction (±x), the fluid flow direction (±x) being perpendicular to an optical fiber draw direction (z);a second stack (152) selectively movable in the fluid flow direction (±x), the first stack (102) and the second stack (152) being selectively movable toward each other, the first stack (102) and the second stack (152) further being selectively movable away from each other;a path (602) for drawing an optical fiber, the path (602) extending in the optical fiber draw direction (z), the path (602) being located between the first stack (102) and the second stack (152);a first set of interlacing structures (842) located on the first stack (102);a second set of interlacing structures (942) located on the second stack (152), the second set of interlacing structures (942) for structurally coupling with the first set of interlacing structures (842) without physically touching the first set of interlacing structures (842), the second set of interlacing structures (942) for interlacing with the first set of interlacing structures (842) as the first stack (102) and the second stack (152) move toward each other;a first set of fluid channels (822) located in the first stack (152), the first set of fluidchannels (822) for introducing a first fluid into the path (602), the first fluid being introduced in a first fluid flow direction (+x), the first fluid flow direction being transverse to the optical fiber draw direction (z), the fluid further being introduced at a first fluid flow rate, the first fluid flow rate and the first fluid flow direction (+x) producing a first physical impact on an optical fiber position during the optical fiber draw; anda second set of fluid channels (922) located in the second stack (152), the second set of fluid channels (922) for introducing a second fluid into the path (602), the second fluid being introduced in a second fluid flow direction, the fluid further being introduced at a second fluid flow rate, the second fluid flow rate and the second fluid flow direction producing a second physical impact on the optical fiber position during the optical fiber draw, the second physical impact substantially counteracting the first physical impact.

9. The system (100) of claim 8, wherein the second stack (152) is movable independently of the first stack (102).

10. The system (100) of claim 8, wherein:the first stack (102) comprises:a first set of blocks (202a . . . 202n), each of the first set of fluid channels (822) being located in a corresponding one of the first set of blocks (202a . . . 202n); anda first set of spaces (232a . . . 232m) interleaved with the first set of blocks (202a . . .202n) to form the first set of interlacing structures (842); andthe second stack (152) comprises:a second set of blocks (302a . . . 302n), each of the second set of fluid channels (922) being located in a corresponding one of the first set of blocks (302a . . . 302n); anda second set of spaces (332a . . . 332m) interleaved with the second set of blocks (302a . . . 302n) to form the second set of interlacing structures (942).

11. The system (100) of claim 8, wherein the fluid is a gas.

12. The cooling system (100) of claim 8, further comprising a cooling efficiency that is greater than five times (>5x) a cooling efficiency of an ambient environment.

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