Optical Fiber Shape Sensing Fabrication via Liquid Coating
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Solution Overview
Problem
Existing optical fiber devices for two- or three-dimensional shape sensing face challenges in maintaining precise geometrical relationships between optical fibers, leading to variations in strain measurements and accuracy in curvature calculations.
Innovation Solution
A method and system for fabricating optical fiber devices involving the positioning of optical fibers in a given geometrical relationship, followed by the deposition and setting of a liquid coating material around them, which maintains this relationship, using techniques like extrusion and inscription of optical gratings to enhance strain measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical fibers are positioned manually or using conventional methods, then the fabrication process is simple, but the positioning precision and geometrical relationship consistency deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-positioning the optical fibers in the desired geometrical relationship within the mold cavity before injecting the coating material. The mold is designed with precise positioning features that hold the fibers in place during the coating process, ensuring consistent geometrical relationships without requiring complex post-processing or adjustment mechanisms.
Solution Approach 2:
The patent introduces a mold as an intermediary device that facilitates precise fiber positioning and maintains the geometrical relationship during coating. The mold acts as a mediator between the fiber positioning requirement and the coating deposition process, providing a structured environment that ensures manufacturing precision while keeping the overall system manageable.
2Stability of the object's composition
If liquid coating material is deposited around optical fibers to maintain geometrical relationship, then positioning consistency improves, but the fabrication process complexity increases
Solution Approach 1:
The patent utilizes phase transitions of the coating material, which is injected in a liquid or semi-liquid state to flow around and encapsulate the optical fibers, maintaining their geometrical relationship. The coating material then cures or solidifies in place, locking the fibers in their precise positions. This phase change from liquid to solid provides a simple yet effective mechanism for achieving consistent geometrical relationships without complex positioning mechanisms.
3Measurement precision
If optical gratings are inscribed on optical fibers, then strain measurement accuracy improves, but the manufacturing process time increases
Solution Approach 1:
The patent merges the coating deposition process with the optical grating inscription process by applying the coating material after the gratings are already inscribed on the optical fibers. The coating is deposited in a manner that does not damage or degrade the previously inscribed gratings, thereby preserving measurement accuracy while avoiding the need for separate, time-consuming processing steps.
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 solution ensures precise positioning and reduced variations in optical fiber placement, resulting in improved accuracy in shape sensing applications by maintaining the geometrical relationship and enhancing strain measurement sensitivity through the use of optical gratings.
Implementation Method 1
the liquid coating material setting up around the longitudinal portions of the plurality of optical fibers thereby maintaining said given geometrical relationship
Implementation Method 2
inscribing one or more optical gratings along a portion of each of the plurality of optical fibers
Data Source
AI summary
There is described a method of fabricating an optical fiber device, the method comprising: positioning longitudinal portions of a plurality of optical fibers alongside each other in a given geometrical relationship, depositing liquid coating material around the longitudinal portions of the plurality of optical fibers; and the liquid coating material setting up around the longitudinal portions of the plurality of optical fibers thereby maintaining said given geometrical relationship along the longitudinal portions.