Metal-Coated Optical Fiber Embedding in Arc-Deposited Structures

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Solution Overview

Problem

Existing methods for integrating optical fibers into metallic structures are cumbersome, costly, and damaging to the fibers due to high temperatures, especially when embedding them deeply, affecting structural integrity and requiring numerous layers for adequate sensing.

Innovation Solution

A method using direct energy deposition (DED-Arc or WAAM) to integrate an optical fiber coated with a high-melting-temperature metallic coating into a metallic structure, where the filler metal matches the structure's composition, ensuring the fiber is surrounded and protected, allowing for precise embedding without damaging the fiber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fusion welding is used to deposit metal on the optical fibre, then the metal can be consolidated effectively, but the optical fibre is damaged due to high welding temperatures

Engineering Contradiction:

Improvemetal consolidationVSAvoidthermal damage to optical fibre

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A metallic coating layer is applied to the optical fibre as an intermediary between the fibre and the molten filler metal. This coating layer has a melting temperature higher than the filler metal, allowing it to withstand the welding heat and prevent thermal damage to the optical fibre while enabling effective metal consolidation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The melting temperature parameter of the coating material is specifically selected to be higher than the filler metal's melting temperature. This parameter change allows the coating to remain solid during the welding process, protecting the optical fibre from thermal damage while enabling the filler metal to melt and bond effectively.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If ultrasonic bonding is used to deposit metal foils on the optical fibre, then the optical fibre is not damaged, but the deposited thickness is very small requiring many layers

Engineering Contradiction:

Improvethermal damage avoidanceVSAvoiddeposited thickness

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The mechanical ultrasonic bonding process is replaced with a thermal direct energy deposition process. This substitution allows for greater deposition thickness in a single operation while still protecting the optical fibre through the use of a high-melting-point metallic coating that acts as a thermal barrier.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple layers are deposited to embed the fibre at required depth, then the fibre is protected, but the process becomes time-consuming and complex

Engineering Contradiction:

Improvefibre protectionVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

A metallic coating is applied to the optical fibre in advance before the embedding process. This preliminary action provides immediate protection and enables single-pass direct energy deposition at the required depth, eliminating the need for multiple sequential layer deposits and significantly reducing manufacturing time and process complexity.

Inventive Principle:

Principle #10Preliminary action

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 method enhances structural monitoring reliability, reduces manufacturing time and cost, and enables scalable monitoring without increasing weight, while maintaining structural integrity.

Implementation Method 1

a direct energy deposition process in which an arc welding source is used to continuously melt and deposit the metal in wire form

Methodology Applied

Scientific EffectArc welding: Electric Arc

Implementation Method 2

The deposition of the molten filler metal is carried out by a direct energy deposition process

Methodology Applied

Scientific EffectDirect energy deposition:

Implementation Method 3

the composition of said metallic coating is selected so that said metallic coating does not melt when said filler metal is deposited, and is selected such that it comprises a melting temperature higher than the temperature of the molten filler metal when deposited

Methodology Applied

Scientific EffectThermal protection through melting point differential: Melting

Data Source

PatentEP4579207A1Method and device for integrating an optical fiber into a metal structure

Publication Date: 2025.07.02 LORTEK S COOP

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Figure 3

AI summary

The invention relates to a method and device for integrating an optical fibre into a metallic structure, wherein the optical fibre (1) is disposed in a channel (2.0) of the metallic structure (2) being coated with a metallic coating, and a molten filler metal (3) is deposited on said channel (2.0) and on said optical fibre (1), by a direct energy deposition process in which an arc welding source (4) is used to continuously melt and deposit the filler metal (3). The metallic coating of the optical fibre (1) comprises a metal with which the filler metal (3) contacts when it is deposited, said metal comprises a melting temperature above the temperature used in the deposition process. The filler metal (3) is composed of the same metal as the metal structure (2).