Segmented Preform Assembly for Multicore Optical Fiber Drawing
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Solution Overview
Problem
Conventional methods for manufacturing multicore optical fibers face challenges such as high complexity, cost, and length restrictions due to precise drilling requirements, leading to increased scrap rates and complexity in maintaining accuracy and uniformity, especially in longer lengths.
Innovation Solution
A preform assembly comprising a hollow cylindrical tube with stacked discs having through holes, where core rods are inserted, allowing for drilling and assembly that minimizes length constraints and complexity by collapsing and stretching the assembly under vacuum pressure to draw multicore or holey optical fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass drilling process is used to manufacture multicore optical fibres, then core rods can be inserted into preformed holes, but the process becomes very costly and complex for longer lengths of preforms
Solution Approach 1:
The preform is divided into multiple shorter sections, each drilled separately with standard drilling equipment. These segmented preforms are then stacked and collapsed together to form the final long multicore optical fibre. This segmentation allows using simple drilling machines for each section rather than requiring complex long-length drilling equipment.
Solution Approach 2:
The problem is solved by transitioning from a single-dimension approach (drilling one long preform) to a multi-dimensional approach (stacking multiple shorter preforms in sequence). The longitudinal dimension is broken into discrete segments that can be manufactured independently and then assembled through collapsing, effectively adding the assembly dimension to the manufacturing process.
2Productivity
If glass drilling process is used for long preforms, then multicore fibres can be produced, but scrap rate increases due to cracks and stress
Solution Approach 1:
By dividing the long preform into multiple shorter sections, each section is drilled and manufactured separately. This segmentation prevents stress and cracks from propagating through the entire length, as each short section can be independently managed and quality-controlled, thereby reducing overall scrap rate.
Solution Approach 2:
The preforms are drilled and prepared in advance as separate short sections before final assembly. This preliminary action allows each section to be fully inspected and validated before being stacked and collapsed, ensuring that only defect-free sections are combined into the final product.
3Adaptability or versatility
If conventional stacking process is used with core rods of different dimensions, then multicore fibres can be manufactured, but manufacturing complexity and time increase
Solution Approach 1:
The invention uses core rods of uniform dimensions and specifications for all stacking operations. This homogeneity simplifies the stacking process by eliminating the need to handle, sort, and position rods of varying sizes, thereby reducing manufacturing complexity and time while maintaining the ability to produce different fibre configurations through arrangement rather than dimension variation.
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 enables scalable and cost-effective manufacturing of multicore optical fibers by reducing the complexity and cost associated with long-length drilling, while maintaining accuracy and uniformity, thus facilitating wider adoption.
Implementation Method 1
collapsing and stretching the assembly under vacuum pressure to draw multicore or holey optical fibers
Data Source
AI summary
The present invention discloses a preform assembly and a method for drawing a multicore optical fibre and a holey fibre. Particularly, the preform assembly includes a hollow cylindrical tube, a plurality of discs stacked inside the hollow cylindrical tube and a plurality of core rods inserted in a plurality of through holes in each of the plurality of discs.