Optical Fiber Ribbon Manufacturing Temperature Control
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Solution Overview
Problem
Existing methods for manufacturing optical fiber ribbons of the partial splice type face issues with forming split portions, leading to insufficient strength and length variation in splice portions, which affect bending anisotropy, workability, and transmission characteristics.
Innovation Solution
A device and method involving a temperature-controlled tape die and split die, where the tape die is set higher than the split die, to control the photocurable resin's viscosity and prevent defects in split and splice portions, ensuring proper curing and alignment of optical fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a photocurable resin is used when forming splice portions at spaced points, then the manufacturing process can be simplified, but the split portions may fail to form properly, splice portions may have insufficient strength, and variation in length among splice portions or split portions may occur
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the tape die and split die differently. The tape die is maintained at a higher temperature to keep the photocurable resin in a low-viscosity state for proper coating, while the split die is maintained at a lower temperature to increase resin viscosity for clean splitting. This temperature parameter differentiation resolves the contradiction between ease of manufacture and manufacturing precision.
Solution Approach 2:
The patent implements local quality by creating different thermal environments in different zones of the manufacturing system. The tape die region has higher temperature for resin application, while the split die region has lower temperature for resin solidification and splitting. This localized temperature control enables both easy manufacturing and high precision in split portion formation.
2Ease of manufacture
If the photocurable resin is used for forming splice portions, then the manufacturing process becomes easier, but the splice portions may have insufficient strength causing tape width variation and optical fibers to come apart
Solution Approach 1:
The patent uses parameter changes by controlling resin viscosity through temperature differentiation. The higher temperature at the tape die ensures proper resin flow and coating, while the lower temperature at the split die increases viscosity to ensure strong bonding and prevent fiber separation. This resolves the contradiction between manufacturing ease and splice strength.
3Ease of manufacture
If variation in length among splice portions or split portions occurs, then the manufacturing process may be simpler, but the transmission characteristics of the optical fibers may be lowered
Solution Approach 1:
The patent applies parameter changes through temperature control to maintain consistent resin viscosity during the splitting process. The lower temperature at the split die ensures uniform resin solidification and consistent split portion length, preventing transmission characteristic degradation while maintaining manufacturing simplicity.
4Manufacturing precision
If the temperature of the tape die is higher than the temperature of the split die, then the photocurable resin viscosity is properly controlled, but additional temperature control complexity is introduced
Solution Approach 1:
The patent implements local quality by applying different temperature conditions to different components (tape die vs. split die). This localized temperature differentiation achieves precise resin viscosity control without requiring complex overall system control, as each component has a simple dedicated temperature setting.
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 inhibits the worsening of bending anisotropy and workability, maintaining stable collective connectability and transmission characteristics of optical fibers during post-branching.
Implementation Method 1
a light irradiation device for irradiating the photocurable resin with light to cure the photocurable resin
Implementation Method 2
both the tape die and the split die are temperature-controlled or only the split die is temperature-controlled, a temperature of the tape die is higher than a temperature of the split die
Data Source
AI summary
An optical fiber ribbon manufacturing device comprising: a tape die 20 for coating a plurality of single-core coated optical fibers 2 with a photocurable resin; a split die 30 for forming a split portion in the photocurable resin present between the single-core coated optical fibers; and a light irradiation device 40 for irradiating the photocurable resin with light to cure the photocurable resin, wherein both the tape die 20 and the split die 30 are temperature-controlled or only the split die 30 is temperature-controlled, a temperature of the tape die 20 is higher than a temperature of the split die 20, and the temperature of the split die 20 is lower than the temperature of the tape die 30.