Optical Fiber Coating Curing via Non-Contact Direction Changer
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Solution Overview
Problem
Increasing the drawing speed of optical fibers while maintaining the integrity of the coating layer is challenging due to the limited space in existing factory buildings, as higher speeds reduce the time for cooling and curing, leading to potential deformation and reduced molecular weight of the resin, especially when using ultraviolet-curable resins.
Innovation Solution
The method involves a drawing step followed by a first cooling step, a coating step with a resin precursor, a first curing step, a second cooling step using non-contact direction changers to cool the semi-cured coating layer, and a final curing step, allowing for controlled temperature management and direction changes without physical contact, thereby maintaining the coating layer's desired state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the drawing speed is increased to raise production capacity, then productivity improves, but the time for cooling and curing becomes insufficient, leading to potential deformation of the coating layer and reduced molecular weight of the resin
Solution Approach 1:
The patent divides the curing process into multiple stages by using multiple curing devices arranged in sequence. The coating layer is cured in steps rather than all at once, allowing each stage to complete properly even at high drawing speeds. This segmentation of the curing process ensures complete curing without requiring excessive residence time at any single location.
Solution Approach 2:
The patent transitions from vertical arrangement of devices to horizontal arrangement. By laying the optical fiber horizontally through multiple curing devices in sequence, the system gains space for multiple processing stations without increasing height requirements. This dimensional change allows adequate curing time and multiple cooling zones while maintaining high drawing speed.
2Manufacturing precision
If multiple cooling devices and curing devices are added to maintain cooling and curing time at high drawing speeds, then coating layer quality improves, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple functions into integrated device units. Each curing device is equipped with both curing functionality and associated cooling capabilities. By merging these functions into unified modules arranged horizontally, the system achieves the required cooling and curing performance without proportionally increasing the total number of separate devices.
Solution Approach 2:
The curing devices are designed to perform multiple functions: UV irradiation for curing, and providing controlled cooling environments. The horizontal arrangement allows each device to serve as both a curing station and a cooling zone, reducing the need for separate dedicated cooling devices and simplifying the overall system configuration.
3Ease of operation
If devices are arranged directly below the melting furnace to maintain proper optical fiber positioning, then ease of operation improves, but space utilization is limited and drawing speed cannot be increased
Solution Approach 1:
The patent fundamentally changes the spatial arrangement from vertical (below the furnace) to horizontal (in sequence after the furnace). This dimensional shift allows the optical fiber to traverse multiple processing devices in a linear path, providing sufficient residence time at each station while maintaining ease of operation through systematic arrangement.
Solution Approach 2:
The system is designed to dynamically adapt to high drawing speeds by using a horizontal configuration that allows the fiber to move continuously through multiple stations. Each device is positioned to handle the high-speed passing fiber effectively, with optimized irradiation and cooling zones that work in sequence rather than requiring the fiber to pause or slow down.
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 enables the production of optical fibers with a stable coating layer at increased drawing speeds, preventing deformation and ensuring optimal curing, even in space-constrained environments, by utilizing non-contact direction changers to manage temperature and reduce the risk of coating layer deformation.
Implementation Method 1
a second cooling step of cooling the semi-cured coating layer by at least one non-contact direction changer between the first curing step and the second curing step
Implementation Method 2
an ultraviolet lamp, a UV-LED or the like is employed as the coating curing device
Data Source
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AI summary
The present invention provides an optical fiber manufacturing method including a drawing step of drawing an optical fiber preform to form a bare optical fiber; a first cooling step of cooling the bare optical fiber; a coating step of providing an uncured coating layer containing a resin precursor on an outer periphery of the bare optical fiber; a first curing step of curing the uncured coating layer to form a semi-cured coating layer; a second curing step of further curing the semi-cured coating layer; and a second cooling step of cooling the semi-cured coating layer by at least one non-contact direction changer between the first curing step and the second curing step.