Optical Fiber Tertiary Ink Coating Integration
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Solution Overview
Problem
Traditional optical fibre manufacturing technologies require multiple off-line processes for applying UV curable acrylate polymers, increasing costs and decreasing efficiency, and existing ink layers applied separately contribute to wind defects and adhesion issues.
Innovation Solution
The process involves applying a cured tertiary ink coating layer with a high glass transition temperature during the fibre drawing process, eliminating the need for an extra off-line step and enhancing abrasion and puncture resistance by integrating it with the fibre manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple off-line processes are used for applying UV curable acrylate polymers, then coating quality can be maintained, but manufacturing costs increase and efficiency decreases
Solution Approach 1:
The patent combines multiple separate coating processes into a single integrated off-line process. The apparatus applies both primary and secondary UV curable acrylate polymer coatings in one continuous operation, eliminating the need for multiple separate processing steps while maintaining coating quality and improving manufacturing efficiency
2Ease of manufacture
If ink layers are applied separately in off-line processes, then colour identification is achieved, but wind defects and adhesion issues occur in ribbon cables
Solution Approach 1:
The patent integrates the ink layer application process with the UV curable acrylate polymer coating process. The ink is applied to the fibre before the secondary coating, and both are cured together in a single off-line process, eliminating adhesion issues and wind defects while maintaining colour identification functionality
Solution Approach 2:
The ink layer is applied to the optical fibre before the secondary coating layer is applied. This preliminary application ensures proper adhesion and positioning, preventing wind defects and adhesion issues in the final ribbon cable assembly
3Productivity
If ink coating is applied during fibre drawing, then manufacturing efficiency improves, but glass transition temperature control becomes critical
Solution Approach 1:
The patent specifies precise parameter ranges for the ink coating material, including a glass transition temperature of at least 55°C and specific viscosity ranges at different temperatures. These parameter controls ensure that the ink coating can be successfully applied during fibre drawing while maintaining the required performance characteristics
Solution Approach 2:
The patent utilizes the glass transition temperature of the ink coating material as a critical parameter. By specifying that the glass transition temperature be at least 55°C, the patent ensures the ink maintains appropriate rheological properties during the fibre drawing process, enabling successful integration without compromising 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 approach reduces manufacturing costs, improves fibre performance by minimizing wind defects and enhancing adhesion in ribbon cables, and achieves higher glass transition temperatures for the ink coating, leading to better handling characteristics and increased cure efficiency.
Implementation Method 1
a) A first applicator dye is adapted to apply a desired amount of primary coating material onto the optical waveguide. b) A first curing device is adapted to effect the curing of the primary coating material. c) A second applicator dye is adapted to apply a desired amount of secondary coating material onto the primary coating layer. d) A second curing device is adapted to effect the curing of the secondary coating material.
Data Source
Figure 1~2
Figure 3
Figure 4A~4D
AI summary
An optical fibre and its manufacture are provided. The optical fibre includes an optical waveguide and a cured primary coating layer surrounding the optical waveguide. The optical fibre further includes a cured secondary coating layer surrounding the cured primary coating layer. The optical fibre further includes a cured tertiary ink coating layer surrounding the cured secondary coating layer. The cured tertiary ink coating layer has a glass transition temperature (Tg-ink) of greater than or equal to 75 °C.