UV Resin Bubble Inspection via Decompression
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Solution Overview
Problem
The existing methods for manufacturing optical fibers fail to effectively inspect and ensure the absence of air bubbles in ultraviolet curable resins, leading to increased losses, appearance defects, and manufacturing issues due to uneven resin shrinkage and surface irregularities.
Innovation Solution
A method involving the inspection of ultraviolet curable resin for optical fibers by decompressing a sealed apparatus containing the resin to a predetermined pressure and allowing it to stand for a set time, with the resin being recognized as acceptable if the volume expansion ratio is equal to or less than a threshold, typically 30%, to prevent air bubble formation and subsequent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If air bubbles are not removed from ultraviolet curable resin, then the resin can be used directly for coating optical fiber, but air bubbles form during manufacturing causing loss increase and appearance defects
Solution Approach 1:
The patent applies preliminary action by performing defoaming treatment on the ultraviolet curable resin before coating the optical fiber. The resin is subjected to reduced pressure treatment to remove air bubbles in advance, ensuring that no bubbles remain to cause defects during subsequent manufacturing processes. This pre-treatment eliminates the need for rework and ensures high-quality optical fiber production.
2Ease of operation
If visual inspection is used to detect air bubbles in resin, then the inspection process is simple, but it is difficult to determine whether air is deflated to the required extent and air bubbles may still be present
Solution Approach 1:
The patent replaces the mechanical/visual inspection method with a physical measurement method. Instead of relying on visual observation, the invention uses volume expansion measurement under reduced pressure to objectively quantify the air bubble content in the resin. This substitution provides precise, objective data that accurately determines whether the resin has been sufficiently defoamed, eliminating the subjectivity and limitations of visual inspection.
3Reliability
If defoaming process is performed on ultraviolet curable resin, then air bubbles are removed, but there are no established criteria to determine whether defoaming is sufficient
Solution Approach 1:
The patent applies parameter changes by measuring the volume expansion of the resin under reduced pressure as a quantitative indicator of air bubble content. By monitoring this specific physical parameter (volume change), the invention establishes clear, objective criteria for sufficient defoaming. This approach provides a simple yet effective measurement method that delivers reliable quality assessment without requiring complex inspection systems.
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 effectively prevents air bubble formation and associated defects in the optical fibers, ensuring reliable manufacturing by determining the presence of air bubbles in the resin before coating, thereby reducing loss and appearance issues.
Implementation Method 1
the inside of the sealed apparatus is decompressed to a predetermined pressure... if a ratio of volume expansion of the ultraviolet curable resin for an optical fiber is equal to or less than a predetermined threshold
Data Source
AI summary
A method of inspecting a degree of air bubbles which are mixed into an ultraviolet curable resin for an optical fiber having viscosity of 1.2 Pa·s to 6.2 Pa·s at a temperature of 25±5° C., is performed in such a manner that the ultraviolet curable resin for an optical fiber which is an inspecting target is put into a sealed apparatus, then the inside of the sealed apparatus is decompressed to be a predetermined pressure, and then the sealed apparatus is left to stand as it is for a predetermined time. If a ratio of the volume expansion of the ultraviolet curable resin for an optical fiber is equal to or less than a predetermined threshold, the ultraviolet curable resin for an optical fiber is recognized as an accepted product.