Optical Fiber UV Curing Window for Low Loss and Coating Removal
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Solution Overview
Problem
Insufficient ultraviolet irradiation in the forming step of the primary resin layer leads to increased micro-bending loss, while excessive irradiation causes the resin to adhere to the glass fiber, reducing coating removability in optical fiber manufacturing.
Innovation Solution
A method for manufacturing optical fiber that involves controlling the number of ultraviolet irradiation reactors, normalized output ratio, and irradiation time to ensure the concentration of the photoinitiator in the primary resin layer follows a specific formula, balancing initiation, dark, and reverse reaction rates to suppress micro-bending loss and ensure coating removability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultraviolet irradiation is increased to suppress micro-bending loss, then micro-bending loss is reduced, but coating removability deteriorates due to overcuring
Solution Approach 1:
The patent applies parameter changes by precisely controlling the ultraviolet irradiation conditions (intensity, duration, wavelength) and photoinitiator concentration to achieve optimal curing. By adjusting these parameters, the resin achieves sufficient curing to suppress micro-bending loss while avoiding overcuring that would prevent coating removal, thus resolving the contradiction between reliability and ease of manufacture.
Solution Approach 2:
The patent employs feedback mechanisms through monitoring and measurement of the curing process. By measuring the actual curing degree and comparing it with target values, the system adjusts irradiation parameters in real-time to maintain optimal curing levels. This feedback control ensures the resin is sufficiently cured to suppress micro-bending loss while remaining removable, addressing both requirements simultaneously.
2Ease of manufacture
If ultraviolet irradiation is insufficient to ensure coating removability, then coating removability is improved, but micro-bending loss increases due to inadequate curing
Solution Approach 1:
The patent uses parameter changes by optimizing the photoinitiator concentration and ultraviolet irradiation intensity to achieve complete curing within the required time frame. By carefully selecting these parameters, the resin achieves full curing for micro-bending loss suppression while maintaining removability, eliminating the need to choose between the two requirements.
Solution Approach 2:
The patent applies preliminary action by pre-formulating the resin composition with optimized photoinitiator concentration and preparing the irradiation system with controlled parameters before the actual curing process. This preliminary preparation ensures that when irradiation occurs, the resin achieves optimal curing quickly and uniformly, preventing both undercuring and overcuring, thus simultaneously achieving micro-bending loss suppression and coating removability.
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 effectively suppresses micro-bending loss and ensures coating removability by optimizing ultraviolet irradiation conditions, resulting in improved optical fiber performance.
Implementation Method 1
forming the primary resin layer by curing the resin composition by ultraviolet irradiation reactor(s)
Implementation Method 2
the resin composition including a photoinitiator
Data Source
AI summary
A method for manufacturing an optical fiber including a glass fiber and a primary resin layer, the method includes: applying an ultraviolet curable resin composition; and forming the primary resin layer by curing the resin composition by ultraviolet irradiation reactor(s), wherein a number N of the ultraviolet irradiation reactor(s), a ratio of normalized output φ for each of the ultraviolet irradiation reactor(s), and an irradiation time t (sec) of each of the ultraviolet irradiation reactor(s) in the forming of the primary resin layer satisfy 6.00×10−5≤N*φ*t≤2.88×10−1, wherein a concentration C [mass %] of the photoinitiator in the forming of the primary resin layer is in accordance with formula (1):C=C0*exp(-N*φ*lν*k)*exp(-N*φ*Lv*kD)+C0*(1-exp(-φ*lk+LkDv))*(1-(1+N*lv*4kR*C0*(1-exp(-φ*lk+LkDv)))-1)(1)wherein the initiation reaction rate constant k is from 20 to 100, wherein the dark reaction rate constant kD is 0≤kD≤30, and wherein the reverse reaction rate constant kR is 0≤kR≤10.