U.S. patent application number 10/904062 was filed with the patent office on 2005-04-07 for fabrication of high air fraction photonic band gap fibers.
This patent application is currently assigned to United States of America as represented by the Secretary of the Navy, United States of America as represented by the Secretary of the Navy. Invention is credited to Aggarwal, Ishwar D., Gibson, Daniel, Kung, Frederic H., Pureza, Pablo C., Sanghera, Jasbinder S., Shaw, Leslie B..
Application Number | 20050074215 10/904062 |
Document ID | / |
Family ID | 36228289 |
Filed Date | 2005-04-07 |
United States Patent
Application |
20050074215 |
Kind Code |
A1 |
Sanghera, Jasbinder S. ; et
al. |
April 7, 2005 |
FABRICATION OF HIGH AIR FRACTION PHOTONIC BAND GAP FIBERS
Abstract
A photonic band gap fiber and method of making thereof is
provided. The fiber is made of a non-silica-based glass and has a
longitudinal central opening, a microstructured region having a
plurality of longitudinal surrounding openings, and a jacket. The
air fill fraction of the microstructured region is at least about
40%. The fiber may be made by drawing a preform into a fiber, while
applying gas pressure to the microstructured region. The air fill
fraction of the microstructured region is changed during the
drawing.
Inventors: |
Sanghera, Jasbinder S.;
(Ashburn, VA) ; Pureza, Pablo C.; (Burke, VA)
; Kung, Frederic H.; (Alexandria, VA) ; Gibson,
Daniel; (Greenbelt, MD) ; Shaw, Leslie B.;
(Woodbridge, VA) ; Aggarwal, Ishwar D.; (Fairfax
Station, VA) |
Correspondence
Address: |
NAVAL RESEARCH LABORATORY
ASSOCIATE COUNSEL (PATENTS)
CODE 1008.2
4555 OVERLOOK AVENUE, S.W.
WASHINGTON
DC
20375-5320
US
|
Assignee: |
United States of America as
represented by the Secretary of the Navy
Chief of Naval Research, Office of Counsel Ballston Tower One,
800 North Quincy St
Arlington
VA
|
Family ID: |
36228289 |
Appl. No.: |
10/904062 |
Filed: |
October 21, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10904062 |
Oct 21, 2004 |
|
|
|
10632210 |
Aug 1, 2003 |
|
|
|
Current U.S.
Class: |
385/125 ; 65/388;
65/389; 65/393 |
Current CPC
Class: |
C03B 37/02781 20130101;
C03B 2201/62 20130101; G02B 6/02328 20130101; C03B 2201/60
20130101; C03B 2201/80 20130101; C03B 2201/88 20130101; C03B
2203/14 20130101; C03B 2205/10 20130101; C03B 37/01274 20130101;
C03C 11/00 20130101; C03B 37/0122 20130101; C03B 2203/12 20130101;
C03B 2203/42 20130101; C03C 13/043 20130101; G02B 6/02371 20130101;
G02B 6/02347 20130101; C03B 2201/70 20130101; C03B 2201/86
20130101; C03B 2203/16 20130101; C03B 2201/78 20130101; C03B 37/025
20130101; C03B 2201/84 20130101; G02B 6/02361 20130101 |
Class at
Publication: |
385/125 ;
065/388; 065/389; 065/393 |
International
Class: |
G02B 006/20 |
Claims
What is claimed is:
1. A method of making a fiber comprising the steps of: providing a
preform comprising a non-silica-based glass, wherein the preform is
cylindrical, having a longitudinal central opening and a
microstructured region comprising a plurality of longitudinal
surrounding openings disposed around the central opening; and
wherein the diameter of the central opening is larger than the
diameter of any surrounding opening that is adjacent to the central
opening; pressurizing surrounding openings with a gas; and drawing
the preform into a fiber at an elevated temperature while
maintaining the gas pressure to retain the longitudinal central
opening and the microstructured region; wherein the air fill
fraction of the microstructured region of the fiber is different
from the air fill fraction of the microstructured region of the
preform.
2. The method of claim 1, wherein diameters of the surrounding
openings of the preform are approximately the same.
3. The method of claim 2, wherein the diameter of the central
opening of the preform is at least two times the diameter of the
surrounding openings of the preform.
4. The method of claim 1, wherein the air fill fraction of the
microstructured region of the fiber is larger than the air fill
fraction of the microstructured region of the preform.
5. The method of claim 1, wherein the central opening is
pressurized with the gas.
6. The method of claim 5, wherein the gas pressure in the central
opening is controlled independently from the gas pressure in the
surrounding openings.
7. The method of claim 6, wherein the gas pressure in the central
opening is less than the gas pressure in the surrounding
openings.
8. The method of claim 1, wherein the gas pressure is controlled at
a substantially constant pressure during the drawing step.
9. The method of claim 1, wherein the gas is selected from the
group consisting of inert gases, nitrogen, argon, and helium.
10. The method of claim 1, wherein the gas pressure is maintained
at a pressure that results in a fiber having an air fill fraction
of the microstructured region of at least about 40%.
11. The method of claim 1, wherein the gas pressure is maintained
at a pressure that results in a fiber having an air fill fraction
of the microstructured region of at least about 70%.
12. The method of claim 1, wherein the gas pressure is maintained
at a pressure that results in a fiber having an air fill fraction
of the microstructured region of at least about 90%.
13. The method of claim 1, wherein the preform comprises a jacket
material comprising the non-silica-based glass surrounding the
microstructured region.
14. The method of claim 1, wherein the diameter of the fiber is
from about 80 microns to about 1000 microns.
15. The method of claim 1, wherein the non-silica-based glass is a
chalcogenide glass.
16. The method of claim 1, wherein the non-silica-based glass is
selected from the group consisting of chalcogenide glass, germanate
glass, phosphate glass, tellurite glass, borate glass, antimonate
glass, and halide glass.
17. A fiber comprising non-silica-based glass, comprising: a
longitudinal central opening; a microstructured region comprising a
plurality of longitudinal surrounding openings disposed around the
central opening; and a jacket surrounding the microstructured
region; wherein the air fill fraction of the microstructured region
is at least about 40%.
18. The fiber of claim 17, wherein the air fill fraction of the
microstructured region is at least about 70%.
19. The fiber of claim 17, wherein the air fill fraction of the
microstructured region is at least about 90%.
20. The fiber of claim 17, wherein the non-silica-based glass is a
chalcogenide glass.
21. The fiber of claim 17, wherein the non-silica-based glass is
selected from the group consisting of chalcogenide glass, germanate
glass, phosphate glass, tellurite glass, borate glass, antimonate
glass, and halide glass.
22. The fiber of claim 17, wherein the fiber has a diameter of
about 80 microns to about 1000 microns.
23. The fiber of claim 17, wherein the fiber is a photonic band gap
fiber having a photonic band gap centered beyond a wavelength of
about 2 microns.
24. The fiber of claim 23, wherein the band gap lies within the
wavelength region of from about 2 microns to about 15 microns.
Description
[0001] This application is a continuation-in-part application of
U.S. patent application Ser. No. 10/632,210, filed on Jan. 8, 2003,
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to high air-fraction
non-silica-based glass fibers.
[0004] 2. Description of the Prior Art
[0005] Hollow core photonic band gap (HC-PBG) fibers have been
fabricated from silica glass and reported in the literature (Cregan
et al., "Single-mode photonic band gap guidance of light in air,"
Science, 285(5433), 1537-1539 (1999); Barkou et al., "Silica-air
photonic crystal fiber design that permits waveguiding by a true
photonic bandgap effect," Optics Letters, 24(1), 46-48 (1999);
Venkataraman et al., "Low loss (13 dB/km) air core photonic
band-gap fibre," ECOC, Postdeadline Paper PD 1.1, September, 2002.
All referenced publications and patents are incorporated herein by
reference). FIG. 1 shows a schematic of the cross-section of a
HC-PBG fiber. The periodic layered structure of holes and glass
creates a photonic band gap that prevents light from propagating in
the structured region (analogous to a 2D grating) and so light is
confined to the hollow core. Typically, the periodicity of the
holes is on the scale of the wavelength of light and the outer
glass is used for providing mechanical integrity to the fiber. The
fact that light travels in the hollow core also means that the
losses will be lower so longer path lengths can be used. Also,
non-linear effects will be negligible and damage thresholds will be
higher so that higher power laser energy can be transmitted through
the fiber for military and commercial applications. Also, since
light is guided in the hollow core, an analyte disposed therein
will have maximum interaction with light, unlike traditional
evanescent sensors.
[0006] The periodicity of the holes, the air fill fraction and the
refractive index of the glass dictate the position of the photonic
band gap or gaps, namely the transmission wavelengths guided
through the hollow core. PBG fibers are obtained by first making a
microstructured preform and then drawing this into fiber with the
correct overall dimensions. In some cases, the air fraction needed
in the fiber, and therefore preform, is as high as 90% or even
higher to provide a photonic band gap. An example includes
chalcogenide glass PBG fiber for transmission in the infrared
region beyond 2 .mu.m. Irrespective of the technique used to make
the preform, it is very difficult to make high air fraction
preforms, especially from specialty glasses such as chalcogenides,
halides, chalcohalides, and the like. Unlike silica, which is a
relatively strong material, specialty oxide and non-oxide glasses
may be weaker and become difficult to fabricate, and moreover,
difficult to handle when the air fraction is so high. Consequently,
there needs to be a technique suitable for making high air fraction
fiber, from specialty glasses.
SUMMARY OF THE INVENTION
[0007] One aspect of the invention provides a method of making a
fiber. A preform comprising a non-silica-based glass is provided.
The preform is cylindrical, having a longitudinal central opening
and a microstructured region comprising a plurality of longitudinal
surrounding openings disposed around the central opening. The
diameter of the central opening is larger than the diameter of any
surrounding opening that is adjacent to the central opening. The
surrounding openings are pressurized with a gas. The preform is
drawn into a fiber at an elevated temperature while maintaining the
gas pressure to retain the longitudinal central opening and the
microstructured region. The air fill fraction of the
microstructured region of the fiber is different from the air fill
fraction of the microstructured region of the preform.
[0008] Another aspect of the invention provides a fiber comprising
non-silica-based glass. The fiber comprises a longitudinal central
opening, a microstructured region comprising a plurality of
longitudinal surrounding openings disposed around the central
opening, and a jacket surrounding the microstructured region. The
air fill fraction of the microstructured region is at least about
40%.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A more complete appreciation of the invention will be
readily obtained by reference to the following Description of the
Example Embodiments and the accompanying drawings.
[0010] FIG. 1 shows a cross-section of a PBG fiber.
[0011] FIG. 2 shows a cross-section of a preform.
[0012] FIG. 3 schematically illustrates an apparatus for drawing a
fiber.
[0013] FIG. 4 shows the cross-section of fibers drawn at different
gas pressures.
DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS
[0014] In the absence of any gas pressure above the holes, the hole
diameters can collapse slightly or completely depending upon the
fiber draw temperature and draw rate. For example, at higher
temperatures, the viscosity may be sufficiently low so that surface
tension dominates and leads to a reduction in the hole diameter.
Silica PBG fibers are typically drawn from a preform made by
stacking tubes. Before fiber drawing, the tube ends are sealed
through fusion or placement of some blocking agent. During fiber
drawing, the gas inside the sealed tubes gets hot and builds up
pressure. However, the gas pressure increases continuously with
time as the preform gets shorter. Consequently, the hole diameters
increase continuously in size without control. This is not a good
situation for making uniform quality PBG fiber since the band gap,
and therefore the transmitted wavelength, will vary along the
length of the fiber.
[0015] However, leaving the holes open before and during fiber
drawing, it is possible to apply a constant pressure above the
holes using gas flow to maintain a constant hole diameter, and
moreover, the hole size can be increased in a controlled manner by
increasing the gas pressure. Hence, the air fraction can be
increased to over 90% in the fiber starting with a microstructured
preform with considerably less air fraction (for example, 30%).
From a practical perspective, it is relatively easier to make and
handle a microstructured preform with only 30% air fraction.
[0016] In the first step in the method of the invention, a preform
comprising a non-silica-based glass, also known a specialty glass,
is provided. Suitable glasses include, but are not limited to,
chalcogenide glass, germanate glass, phosphate glass, tellurite
glass, borate glass, antimonate glass, and halide glass.
[0017] The preform is cylindrical. As used herein, the term
"cylindrical" is not limited to round structures, but also refers
to preforms having substantially the same perpendicular outside
cross-section along the entire length of the preform, or along the
length of the preform that is to be drawn into a fiber. The preform
may include head or tail portions that do not have the same
cross-section, or any other stated characteristic, that is
otherwise stated to run the length of the preform, as long as the
characteristic is present in the portion of the preform that is to
be drawn into a desired fiber. Example cylinders include, but are
not limited to, a normal round cylinder and a hexagonal cylinder,
with smooth sides or with sides made of half circles.
[0018] The preform has a longitudinal central opening or hole that
runs the length of the preform, which is hollow. The central
opening may or may not be centered in the preform. Surrounding the
central opening and running the length of the preform is a
microstructured region comprising a plurality of hollow,
longitudinal central openings. The microstructured region may or
may not be radially symmetrical. Certain surrounding openings are
adjacent to the central opening in that they are in a first layer
of openings around the central opening. This layer is between the
central opening and any non-adjacent surrounding openings. For
example, when the microstructured region is a hexagonal arrangement
of surrounding openings, the adjacent openings are those in the
hexagon immediately surrounding the central opening.
[0019] The preform is constructed so that the central opening is
larger in diameter than that of any of the adjacent surrounding
openings. In some embodiments, all the surrounding openings are
approximately the same size. For example, they may be made from the
same kind of tubing, which inherently has a certain range in its
size from point to point due to imperfect manufacturing, but is
considered to be approximately the same size at all points. In some
of these embodiments, the central opening has at least two times
the diameter of the surrounding openings.
[0020] In some embodiments, the preform also comprises a jacket
material comprising the non-silica-based glass. The jacket can help
to protect the potentially fragile microstructured region of both
the preform and the fiber and provide mechanical integrity.
[0021] A cross-section of a suitable preform is shown in FIG. 2.
The preform 10 can be made by stacking tubes 20 of the same size in
a hexagonal structure, leaving seven tubes missing in the center to
form the central opening 30. A larger tube may also be inserted
into the central opening to define a round opening or an opening of
another shape. The entire stack is placed inside a hollow jacket
40, and the entire assembly fused together. The fusing can
substantially eliminate the interstitial voids between tubes with a
circular outer diameter. Alternatively, tubes with a hexagonal
outer diameter may be used so that there are no voids between the
tubes. The adjacent openings are indicated by the "+" symbols. FIG.
1 shows the cross-section of a fiber that may be made from the
preform of FIG. 2. The air faction of the preform may be 41%
compared to an 87% air fraction of the fiber. It is to be
understood that fabrication of the PBG preforms using the tube
stacking technique is only one example of fabricating these
microstructured preforms. Other techniques could be used to
fabricate the PBG preforms.
[0022] In the second step, the central opening and surrounding
openings are pressurized with a gas. This can be done with a gas
supply assembly attached to one end of the preform and the other
end of the preform positioned above a fiber draw furnace. The gas
can be the same or different gases in different openings. Suitable
gases include, but are not limited to, inert gases, nitrogen,
argon, and helium. An inert gas can be used to maintain a passive
environment during processing. Alternatively, a reactive gas can be
used to purify the surface of the openings or modify the
composition on the inside surface of the openings, thereby
adjusting properties such as refractive index, and/or the physical
and thermal properties. The gas pressure in the central opening may
be controlled independently from and may be less than the gas
pressure in the surrounding openings. Consequently, the ratio of
the respective hole diameters can be modified in a controlled
manner.
[0023] In the third step of the invention, the preform is drawn
into a fiber. Note that the steps of pressuring and drawing occur
concurrently, with the possibility that either step can begin
first. The drawing is done at an elevated temperature so that the
glass is softened. The gas pressure maintains and prevents the
collapse of the central opening and the surrounding openings of the
microstructured region. The gas pressure can be controlled at a
substantially constant pressure during the drawing step, so that
the resulting fiber has substantially the same cross-section along
its length.
[0024] The whole fiber drawing furnace can be located inside an
inert atmosphere if drawing specialty glasses where atmospheric
control is important (e.g. chalcogenides and halides). Furthermore,
the fiber drawing assembly can be isolated from environmental
contaminants such as dust and other extraneous particles, which
might have a detrimental impact on fiber strength and/or optical
properties. The preform can be lowered into the furnace at a known
rate while the temperature is gradually increased from a
predetermined temperature to prevent thermal shock of the preform.
Once the temperature is sufficiently high, for example
corresponding to a glass viscosity in the range of about 10.sup.4
to 10.sup.6 Poises, the preform will soften and be drawn into fiber
with considerably smaller dimensions than the starting preform.
[0025] FIG. 3 schematically illustrates a pressurizing and drawing
apparatus. The preform 110 has gas pressure 120 flowing directly
into the central opening, and another source of gas pressure 130
over the microstructured region. The gas pressure 120 may flow
through a tube inserted into the central opening, without any need
to enlarge the openings. The preform 110 is lowered into a fiber
draw furnace 140, from which it emerges as a fiber 150.
[0026] The gas pressure or pressures are chosen so that the air
fill fraction of the microstructured region is different in the
fiber from what it is in the preform, as opposed to merely
maintaining the same air fill fraction and preventing collapse of
the openings. The air fill fraction can be increased by the drawing
step and may be raised to at least as high as 40%, 70%, or 90%,
depending on the air fill fraction of the preform. It is also
possible to apply pressure to the preform before the fiber drawing
to modify the size of the holes in the preform. The required air
pressure to change the air fill fraction or even just to prevent
collapse of the holes can be different than it would be if the
glass were silica, as the surface tension and viscosity of the
non-silica glasses can be different.
[0027] The resulting fiber has a structure similar to the preform,
with a central opening, a microstructured region, and a jacket. The
microstructured region can have an air fill fraction of at least as
40%, 70%, or 90%. The diameter of the fiber may be, but is not
limited to, in a range of 80-1000 .mu.m in diameter. For example,
the diameter of the microstructured preform could be greater than
10 mm whereas the fiber diameter could be less than 200 .mu.m.
[0028] The structure of the fiber can cause it to have the
properties of a photonic bandgap fiber. Light of a wavelength in
the band gap can propagate through the fiber, while being confined
to the central opening. The microstructured region can prevent all
or most of the light from passing through the glass, including any
layer of glass that may be between the central opening and the
adjacent surrounding openings. The band gap may be centered at a
wavelength that is in the infrared, such as longer than 2 microns
and as long as 15 microns.
[0029] The exact air fraction and periodicity in the final fiber
will be controlled by the temperature, viscosity of the glass,
fiber draw rate, and gas pressure. This assumes that the feed rate
of the preform into the hot zone is fixed at a predetermined rate,
which is typical in fiber drawing. It is possible to modify and
control the air fraction and periodicity along with the overall
fiber diameter, thereby controlling the photonic band gap. Another
consequence at high air fraction is that the holes may no longer be
round, but instead more hexagonal. This does not necessarily have a
detrimental impact on the PBG properties.
[0030] Example uses of the fiber include, but are not limited to,
facility clean up, biomedical analysis (e.g. glucose, blood,
breath), CBW agent detection, toxic and hazardous chemical
detection, and environmental pollution monitoring and process
control. In addition to chemical sensing, the PBG fibers can be
used for very high laser power delivery since the light is
predominantly guided in the hollow core, unlike in traditional
fibers, which possess a solid core that can be damaged at high
powers. This may have a positive and enabling impact in next
generation high power infrared missile warning systems. Further
benefits of PBG fibers include reducing system complexity, weight
and cost as well as enabling remoting of high power lasers for
cutting, welding, and metrology, as well as laser surgery, cancer
removal and glaucoma treatment. Infrared lasers for biomedical
applications include the CO.sub.2 laser where powers including, but
not limited to, 10 to 50 W are needed and cannot be transmitted
using current solid core fibers.
[0031] Having described the invention, the following examples are
given to illustrate specific applications of the invention. These
specific examples are not intended to limit the scope of the
invention described in this application.
EXAMPLE 1
[0032] Single tube--A single glass tube made from AS.sub.39S.sub.61
glass was drawn to a fiber under 2.8 in H.sub.2O gas pressure
inside the tube. The ratio of the hole diameter to the outer
diameter of the tube was increased considerably in the fiber by
increasing the pressure in the hole during drawing. The air
fraction was increased from 32% to 85% in this example. It can be
even larger (>90%) depending upon the viscosity, temperature,
draw rate, and pressure. The uniformity and concentricity was not
compromised by this process.
EXAMPLE 2
[0033] Preform--This example pertains to a microstructured preform
made from AS.sub.39S.sub.61 glass having a large central opening
and 12 surrounding openings in a single hexagonal configuration (3
openings per edge of the hexagon). The preform was placed on the
fiber draw tower and attached to gas pressurizing assembly. The
preform was heated up to 310.degree. C. when it softened and fiber
drawing was initiated. The pressure above the microstructured
preform was changed and this caused changes to the hole diameters.
The central core was open to the atmosphere. Increasing the
pressure increased the hole size and therefore air fraction in the
fiber. For example, without gas pressure, the microholes in the
fiber were about 6 .mu.m in diameter. However, the application of a
nitrogen gas pressure equivalent to 2 in H.sub.2O increased the
micro-hole diameter to about 23 .mu.m. The initial size of the
microholes in the preform was about 1 mm diameter. This preform did
not possess an optimized photonic band gap structure, but
nevertheless, this example highlights that real time changes to the
hole diameters, and therefore air fraction, was made during fiber
drawing.
EXAMPLE 3
[0034] Increased gas pressure--This example shows how the air
fraction of a microstructured preform, containing several layers of
holes, can be increased by using gas pressure applied uniformly to
the central opening and surrounding openings during fiber drawing.
The glass was AS.sub.39S.sub.61 and the air fill fraction of the
microstructured region of the preform was 74%. FIGS. 4(a)-(c) show
pictures of microstructured fibers that were drawn using different
pressures. FIG. 4(a) was generated with no gas pressure and
resulted in an air fill fraction of 47%. FIG. 4(b) was generated
with 1 in H.sub.2O of N.sub.2 in both the microstructured region
and the central opening, and resulted in an air fill fraction of
58%. Pressure of 2 and 3 in H.sub.2O of N.sub.2 resulted in air
fill fractions of 67% and 69% respectively. FIG. 4(c) was generated
with 4 in H.sub.2O of N.sub.2 and resulted in an air fill fraction
of 78%. It is clearly evident that increasing the pressure to 4 in
H.sub.2O increased the air fraction as noted by the thinner webbing
between the holes. It is estimated that a pressure of 3.4 in
H.sub.2O would result in no change to the air fill fraction. Even
though this is not an optimized PBG design, it is quite clear that
gas pressure can be used to increase the air fraction in the
fiber.
EXAMPLE 4
[0035] Separate gas pressures--This example pertains to a
microstructured preform made from an arsenic selenide-based glass
having a large central opening and 84 surrounding openings in a
hexagonal configuration, surrounded by a jacket tube. The air
fraction of the microstructured region of the preform was 19% and
the ratio of the central opening diameter to the surrounding
opening pitch was 2.3. In this example, separate gas pressures were
applied to the central opening and the group of 84 surrounding
openings, during the fiber draw. Pressures of 0 and 15 in H.sub.2O
of N.sub.2 applied to the central and surrounding openings
respectively generated a fiber with air fraction of 14% and a ratio
of central opening diameter to surrounding opening pitch of 2.2.
Pressures of 0 and 25 in H.sub.2O of N.sub.2 applied to the central
and surrounding openings respectively generated a fiber with air
fraction of 24% and a ratio of central opening diameter to
surrounding opening pitch of 2.4. This fiber did not possess an
optimized photonic bandgap structure, but nevertheless, this
example highlights that the diameters of the surrounding openings,
and therefore air fraction, can be changed separately from the
diameter of the central opening by applying separate gas pressures
to the surrounding openings as a group, and the central opening
during fiber drawing.
[0036] Obviously, many modifications and variations of the present
invention are possible in light of the above teachings. It is
therefore to be understood that the claimed invention may be
practiced otherwise than as specifically described.
* * * * *