Multi-Core Fiber Preform Manufacturing via Segmented Rod Insertion
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Solution Overview
Problem
The existing manufacturing methods for multi-core fibers often result in breakage of the cladding rod due to reduced thickness between holes, leading to incomplete integration and potential shifts in core positions during heating.
Innovation Solution
A two-step method is introduced where first holes are formed in a cladding rod, a glass rod is inserted and heated to form an intermediate preform, and then second holes are formed and filled with another glass rod, with the second holes positioned closer to the center axis to reduce stress on the cladding rod and ensure accurate integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a plurality of holes are formed in a cladding rod and glass rods are inserted to achieve high core density, then the core density is improved, but the cladding rod thickness between adjacent holes is reduced leading to increased breakage risk
Solution Approach 1:
The manufacturing process is divided into two sequential steps: first forming holes and inserting glass rods to create an intermediate preform, then forming additional holes and inserting more glass rods. This segmentation allows the cladding rod to maintain sufficient thickness during each individual operation while achieving high overall core density through cumulative insertion.
Solution Approach 2:
The first holes are formed and glass rods are inserted into the cladding rod before forming the second holes. This preliminary action creates an intermediate preform structure where the cladding rod has already been modified, allowing subsequent hole formation to occur around existing glass rods rather than through the original thin cladding sections.
2Quantity of substance
If the cladding rod thickness between holes is reduced to increase core density, then the core density is improved, but the manufacturing precision deteriorates due to breakage and position shifts
Solution Approach 1:
The hole formation and glass rod insertion process is segmented into two distinct manufacturing steps. The first step creates initial holes and inserts glass rods to form an intermediate preform. The second step then forms additional holes and inserts remaining glass rods. This segmentation prevents the cladding rod from experiencing excessive stress that would cause breakage or position shifts, thereby maintaining manufacturing precision while achieving high core density.
Solution Approach 2:
The intermediate preform is created as a preliminary structure before completing all hole formations and glass rod insertions. This intermediate state allows the manufacturing process to proceed with better structural support, reducing the risk of position shifts and breakage that would compromise manufacturing precision.
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 method effectively reduces the likelihood of cladding rod breakage and ensures precise integration of glass rods, maintaining high core density and preventing core position shifts during the manufacturing process.
Implementation Method 1
heating the cladding rod together with the inserted first glass rod to integrate the first glass rod and the cladding rod
Implementation Method 2
heating the cladding rod together with the inserted first glass rod to integrate the first glass rod and the cladding rod
Implementation Method 3
heating the intermediate preform together with the inserted second glass rod to integrate the second glass rod and the intermediate preform
Implementation Method 4
heating the intermediate preform together with the inserted second glass rod to integrate the second glass rod and the intermediate preform
Data Source
AI summary
A manufacturing method includes forming one or more first holes in a cladding rod, inserting a first glass rod into each of the one or more first holes, heating the cladding rod together with the inserted first glass rod to integrate the first glass rod and the cladding rod and to form an intermediate preform, forming one or more second holes in the intermediate preform, inserting a second glass rod into each of the one or more second holes, and heating the intermediate preform together with the inserted second glass rod to integrate the second glass rod and the intermediate preform.