Optical Fiber Cooling System for High-Speed Draw Quality

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Solution Overview

Problem

Increasing the rate of optical fiber draw in manufacturing processes leads to higher temperatures and decreased quality due to reduced cooling time, necessitating improved methods for controllably cooling optical fibers during the draw process.

Innovation Solution

A method involving a first cooling device that directs fluid to contact the optical fiber to cool it rapidly, followed by a second cooling device, where the optical fiber is conveyed at high velocities, allowing for controlled cooling rates and diameter adjustments to improve fiber quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the draw rate is increased to meet consumer demand, then productivity is improved, but the temperature of the optical fiber increases and quality decreases

Engineering Contradiction:

Improveoptical fiber production rateVSAvoidoptical fiber temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The cooling process is divided into two distinct stages: a first cooling device that provides rapid cooling at high draw rates, and a second cooling device that provides controlled cooling. This segmentation allows the system to handle high productivity requirements while maintaining temperature control and fiber quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the cooling rate parameter dynamically - using a first cooling rate greater than 10000° C./s in the first cooling device, then transitioning to a second cooling rate less than 5000° C./s in the second cooling device. This parameter change enables effective temperature management at increased draw rates.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the draw rate is increased to meet consumer demand, then productivity is improved, but the cooling time is reduced and quality decreases

Engineering Contradiction:

Improveoptical fiber production rateVSAvoidcooling time

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The first cooling device performs preliminary rapid cooling immediately after the fiber leaves the draw tower, removing the bulk of the heat quickly. This preliminary action compensates for the reduced total cooling time caused by higher draw rates, preventing quality degradation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention maintains continuous cooling action through two sequential cooling devices - the first cooling device operates continuously at high cooling rates, followed by the second cooling device that continues the cooling process. This continuous useful action ensures quality maintenance despite reduced residence time in the cooling zone.

Inventive Principle:

Principle #20Continuity of useful action

3Temperature

If rapid cooling is applied to maintain quality at high draw rates, then temperature control is improved, but the fiber diameter may change excessively

Engineering Contradiction:

Improveoptical fiber temperature controlVSAvoidoptical fiber diameter

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

Different cooling rates are applied at different stages of the cooling process - rapid cooling (>10000° C./s) in the first cooling device for initial temperature reduction, then controlled cooling (<5000° C./s) in the second cooling device for diameter stabilization. This local quality approach in the cooling process maintains both temperature control and dimensional stability.

Inventive Principle:

Principle #3Local quality

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 cools the optical fiber at high rates, maintaining quality by reducing fictive temperatures and enhancing attenuation characteristics, enabling increased production without compromising fiber properties.

Implementation Method 1

directs fluid to contact the optical fiber to cool it rapidly

Methodology Applied

Scientific EffectFluid cooling: Convection

Implementation Method 2

the optical fiber having a first diameter at the first inlet and a second diameter at the first outlet

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentUS11554979B2Methods and systems for processing optical fiber

Publication Date: 2023.01.17 CORNING INC

AI summary

A system for processing optical fiber includes a draw furnace, a fiber conveyance pathway extending between an upstream end positioned at the draw furnace and a downstream end positioned opposite the upstream end, where optical fiber is conveyed along the fiber conveyance pathway from the upstream end to the downstream end in a fiber conveyance direction, a muffle in communication with the draw furnace and positioned downstream of the draw furnace, a second cooling device annularly surrounding the fiber conveyance pathway downstream from the draw furnace, the second cooling device including one or more second cooling device heating elements and a first cooling device positioned between the draw furnace and the second cooling device, wherein the first cooling device directs a fluid to contact the optical fiber.