Extrusion Method for All-Solid-State Photonic Crystal Fiber Preforms
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Solution Overview
Problem
The existing method for preparing all-solid-state photonic crystal fiber preforms, specifically infrared-soft-glass-based ones, using the stacking-capillary method results in severe deformation, core-cladding interface defects, and high optical loss due to air impurities and oxidation issues.
Innovation Solution
A method involving extrusion to form a core array and co-extrude with cladding glass using a specifically designed mold and temperature control, ensuring precise core-cladding integration and minimizing air exposure to improve surface quality and structural stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stacking-capillary method is used to prepare all-solid-state PCF preforms, then the preforms can be manufactured, but severe deformation occurs and core-cladding interface defects are generated
Solution Approach 1:
The patent changes the fundamental manufacturing parameters by switching from a stacking-capillary method to an extrusion method. The extrusion process uses controlled temperature (near glass softening temperature) and pressure parameters to form the preform, achieving better core-cladding interface quality while maintaining manufacturability. The core glass and cladding glass are extruded simultaneously under controlled conditions, preventing the severe deformation and interface defects associated with stacking methods.
Solution Approach 2:
The patent replaces the mechanical stacking and assembly process with a continuous extrusion process. Instead of manually or mechanically stacking capillaries and then sintering them (which causes deformation and interface defects), the invention uses an extrusion die system where glass materials are pushed through a shaped opening under controlled pressure and temperature, forming the preform in a single continuous operation with superior interface quality.
2Ease of manufacture
If the stacking-capillary method is used to prepare all-solid-state PCF preforms, then the preforms can be manufactured, but high optical loss occurs due to air impurities and oxidation
Solution Approach 1:
The patent implements an inert atmosphere protection system during the extrusion process. The glass materials are extruded in a controlled environment that prevents air impurities and oxidation from contaminating the glass surfaces. This inert environment eliminates the high optical loss associated with air exposure during manufacturing, while the continuous extrusion process maintains manufacturability.
Solution Approach 2:
The patent extracts or removes air impurities and oxidation hazards from the manufacturing environment by using an inert atmosphere system. The harmful air components are excluded from the extrusion zone, preventing contamination of the glass preform and eliminating the source of optical loss, while the manufacturing process continues efficiently.
3Ease of manufacture
If the stacking-capillary method is used to prepare all-solid-state PCF preforms, then the preforms can be manufactured, but structural deformation occurs
Solution Approach 1:
The patent replaces the multi-step mechanical stacking and sintering process with a single continuous extrusion process. The glass materials are pushed through a precisely engineered die under controlled pressure and temperature, forming the preform structure in one operation. This eliminates the cumulative deformation that occurs during stacking, alignment, and sintering of separate capillary components.
Solution Approach 2:
The patent changes the processing parameters from low-temperature stacking and high-temperature sintering (which cause deformation) to a controlled extrusion process near the glass softening temperature. The continuous extrusion under controlled pressure and temperature maintains the structural integrity and prevents deformation, while the process remains manufacturable through automation.
4Manufacturing precision
If the extrusion method is used to prepare all-solid-state PCF preforms, then deformation is reduced and interface quality is improved, but the process complexity increases
Solution Approach 1:
The patent merges multiple operations (heating, extrusion, shaping, and cooling) into a single integrated extrusion process. The glass materials are fed into a heated extrusion die, pushed through the shaped opening to form the preform, and cooled in sequence without requiring separate handling or assembly steps. This consolidation improves interface quality while the integrated nature of the process actually reduces overall system complexity compared to multiple separate operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces deformation, enhances core-cladding interface clarity, and minimizes optical losses, resulting in higher purity and quality fiber preforms with controlled core distributions and compatible thermal properties.
Implementation Method 1
an array of neatly-arranged glass columns can be extruded from core glass in a specifically-designed core outlet mold at a temperature near the glass softening temperature
Implementation Method 2
the array of glass columns and the cladding glass are co-extruded to obtain fiber preform
Implementation Method 3
at a temperature near the glass softening temperature
Data Source
AI summary
A method for preparing all-solid-state photonic crystal fiber preform by extrusion by aligning the center of the first jacking end of the first jacking rod with the center of the core outlet mold. The adverse effect on this part of extruded core glass by oxygen or other impurities in air during the extrusion out of the core outlets can be avoided. The defects on the core glass surface and the cladding glass surface can be effectively removed, and the purity and quality of the core component in the obtained fiber preform can be improved.