Flexible Optical Fiber Ribbon With Optical Bonding Detection
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Solution Overview
Problem
Existing methods for detecting bonding performance in flexible optical fiber ribbons are inadequate due to misaligned adhesive dots, missing adhesive, and adhesive dispensing defects, which are not effectively identified by high-speed imaging, leading to poor structural stability and manufacturing inefficiencies.
Innovation Solution
A flexible optical fiber ribbon structure with a transparent light-transmitting layer and color layer, combined with a light detection system, uses optical signals for on-off detection to assess bonding performance without imaging, ensuring high-speed quality detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high-speed imaging is used to detect bonding performance, then detection speed can keep pace with manufacturing speed, but image quality deteriorates due to trailing effects and artifacts from limited shutter speed
Solution Approach 1:
The patent replaces the mechanical imaging system with an optical detection system. Instead of using cameras to capture images of bonding parts, the system uses light sources and photodetectors to directly detect light transmission through the bonding material. This substitution eliminates the need for high-speed imaging while achieving both high detection speed and accurate bonding quality assessment.
Solution Approach 2:
The patent introduces light as an intermediary to detect bonding performance. By measuring light transmission through the bonding parts, the system indirectly assesses bonding quality without needing to directly image the bonding material. This intermediary approach allows for high-speed detection while maintaining measurement precision.
2Measurement precision
If visual inspection is used to detect adhesive defects, then bonding quality can be assessed, but detection speed cannot keep pace with high manufacturing speed of 2-10 m/s
Solution Approach 1:
The patent replaces visual inspection with optical detection. Instead of using cameras and image processing algorithms that cannot keep up with high manufacturing speeds, the system uses light transmission measurement which provides instantaneous detection results. This enables the detection system to operate at the same high speeds as the manufacturing process.
3Measurement precision
If imaging systems are used for detection, then bonding defects can be identified, but system complexity and cost increase due to high-speed camera requirements
Solution Approach 1:
The patent replaces complex high-speed imaging systems with simple optical detection components. Instead of requiring high-speed cameras, triggers, and image processing hardware, the system uses basic light sources and photodetectors. This substitution dramatically reduces system complexity while maintaining the ability to identify bonding defects.
4Productivity
If adhesive dispensing is performed at high speed with short pitch, then manufacturing efficiency is improved, but adhesive placement accuracy deteriorates due to equipment stability and adhesive quality issues
Solution Approach 1:
The patent implements a feedback mechanism where the optical detection system continuously monitors bonding quality and provides real-time information about adhesive placement accuracy. This feedback enables process control adjustments to compensate for variations in adhesive dispensing, maintaining placement accuracy even at high manufacturing speeds with short pitch distances.
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
The solution provides sensitive, accurate, and high-speed detection of bonding performance, reducing production line costs and improving manufacturing efficiency by eliminating imaging drawbacks and material complexity.
Implementation Method 1
The color layer has a transmittance of 30% or lower for the wavelength band of the detection light, and the light-transmitting layer has a transmittance of 85% or higher for the wavelength band of the detection light
Data Source
AI summary
A flexible optical fiber ribbon includes multiple optical fibers arranged side by side, with intermittent bonding parts between adjacent optical fibers. The transmittance of the intermittent bonding parts for a wavelength band of a detection light is 50% or lower. The optical fiber coating is covered with a color layer, and the color layer is covered with a light-transmitting layer. The transmittance of the color layer for the wavelength band of the detection light is 30% or lower, and the transmittance of the light-transmitting layer for the wavelength band of the detection light is 85% or higher. The bonding parts with qualified bonding performance cover the light-transmitting layer in the detection light direction.