Laser-Processed Optical Fiber Ribbon for High-Speed Intermittent Bonding
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Solution Overview
Problem
Existing methods for manufacturing intermittent bonding type optical fiber ribbons face limitations in manufacturing speed due to the speed of applying bonding members, such as dispensers and shutter mechanisms, which restrict the linear velocity of coated optical fibers.
Innovation Solution
A method involving the use of a laser light absorbing component in the resin composition, combined with pulse laser light irradiation, to form non-connection and intermittent connection portions between coated optical fibers, allowing for high-speed manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a buffer layer is formed between the substrate and the core layer to suppress crystallization, then core layer crystallization is suppressed, but the buffer layer consumes production time and adds process complexity
Solution Approach 1:
The patent extracts and removes the buffer layer from the structure, instead using a specific substrate composition (containing ZnO, SiO2, and B2O3 in defined ratios) that inherently prevents core layer crystallization without requiring a separate buffer layer, thus eliminating the time-consuming buffer layer formation process
Solution Approach 2:
The substrate is given multiple functions: it serves as both the base support and the crystallization-suppressing layer that previously required a separate buffer layer, achieving the same effect while simplifying the overall structure and reducing production steps
2Reliability
If a buffer layer is formed between the substrate and the core layer, then core layer crystallization is suppressed, but the number of production steps increases
Solution Approach 1:
The patent extracts and removes the buffer layer from the production process, replacing it with a specially formulated substrate composition that provides the same crystallization suppression function, thereby reducing the number of production steps
Solution Approach 2:
The patent merges the functions of the substrate and the buffer layer into a single multi-functional substrate layer, combining the structural support role with the crystallization suppression role, thus eliminating the need for separate buffer layer formation steps
3Object-affected harmful factors
If the core layer is made thin to reduce cladding mode noise, then cladding mode noise is reduced, but coupling loss increases
Solution Approach 1:
The patent applies local quality by creating a refractive index profile where the cladding layer has a higher refractive index than the core layer in specific regions, allowing the core layer to be thin (for noise reduction) while the localized refractive index modification compensates for coupling loss
Solution Approach 2:
The patent changes the refractive index parameter of the cladding layer (making it higher than the core layer) to compensate for the reduced core layer thickness, thereby maintaining coupling efficiency while minimizing cladding mode noise
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 rapid formation of non-connection and intermittent connection portions, maintaining high linear velocity and ensuring the integrity of the optical fiber ribbon during high-density mounting without damaging cable characteristics.
Implementation Method 1
a buffer layer between the substrate and the core layer to suppress crystallization of the core layer
Implementation Method 2
optical fiber intermittent tape core comprising a substrate, a core layer, and a cladding layer
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
To provide a method for manufacturing an intermittent bonding type optical fiber ribbon, which can also be used for manufacturing with high linear velocity, and the intermittent bonding type optical fiber ribbon. The present invention is a method for manufacturing an intermittent bonding type optical fiber ribbon 2 which is capable of conveniently forming non-connection portions 4 and intermittent connection portions 3 between adjacent coated optical fibers 1 formed into an optical fiber ribbon by performing a laser processing for the ribbon through the irradiation with the pulse laser light, thereby making it possible to rapidly form the intermittent connection portions 3 and the non-connection portions 4 while maintaining high linear velocity of the coated optical fiber 1 or a high speed of application of a resin composition applied to connect the adjacent coated optical fibers 1 to each other. Further, the non-connection portions 4 and the intermittent connection portions 3 are formed in the obtained optical fiber ribbon 1 through the irradiation with the pulse laser light, such that the optical fiber ribbon 1 becomes the intermittent bonding type optical fiber ribbon 2, which is capable of securing operability during collective connection and surely being subjected to an intermediate branching without damaging cable characteristics during high density mounting.