U.S. patent application number 17/699282 was filed with the patent office on 2022-07-07 for system and method for manufacturing optical fiber.
The applicant listed for this patent is MADE IN SPACE, INC.. Invention is credited to Jan Clawson, Noah Paul-Gin, Nate Pickslay, Geoffrey York Powers, Michael Snyder, Robert White.
Application Number | 20220212978 17/699282 |
Document ID | / |
Family ID | 1000006211011 |
Filed Date | 2022-07-07 |
United States Patent
Application |
20220212978 |
Kind Code |
A1 |
Clawson; Jan ; et
al. |
July 7, 2022 |
SYSTEM AND METHOD FOR MANUFACTURING OPTICAL FIBER
Abstract
A system for precoating a preform for drawing optical fiber
including a diameter sensor to determine a diameter of pulled
optical fiber, a cooling system to cool the optical fiber once it
is pulled from a furnace, a coating system to apply a coating to
the optical fiber once it has cooled and an ultra-violet lamp to
cure the coating.
Inventors: |
Clawson; Jan; (Mountain
View, CA) ; White; Robert; (Sunnyvale, CA) ;
Pickslay; Nate; (Mountain View, CA) ; Snyder;
Michael; (Jacksonville, FL) ; Powers; Geoffrey
York; (Richmond, TX) ; Paul-Gin; Noah; (San
Francisco, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MADE IN SPACE, INC. |
Moffett Field |
CA |
US |
|
|
Family ID: |
1000006211011 |
Appl. No.: |
17/699282 |
Filed: |
March 21, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16045733 |
Jul 25, 2018 |
11312650 |
|
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17699282 |
|
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62536765 |
Jul 25, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C03B 2205/50 20130101;
C03B 37/0216 20130101; C03B 2205/30 20130101; G02B 6/02 20130101;
C03B 2205/80 20130101; C03B 2205/40 20130101; C03B 2205/60
20130101; C03B 2205/72 20130101; C03B 37/029 20130101; B01D 29/56
20130101; C03B 37/032 20130101; C03B 2201/82 20130101; C03C 25/6226
20130101; C03B 37/01211 20130101; C03B 2205/82 20130101; C03C
25/105 20130101; B01D 29/60 20130101; C03C 25/106 20130101; C03C
13/042 20130101; C03B 2205/08 20130101; C03B 37/02736 20130101;
C03B 37/07 20130101; C03B 37/0253 20130101; C03C 13/04
20130101 |
International
Class: |
C03B 37/02 20060101
C03B037/02; C03C 13/04 20060101 C03C013/04; C03C 25/105 20060101
C03C025/105; B01D 29/60 20060101 B01D029/60; B01D 29/56 20060101
B01D029/56; C03B 37/027 20060101 C03B037/027; C03B 37/07 20060101
C03B037/07; C03C 25/106 20060101 C03C025/106; C03C 25/6226 20060101
C03C025/6226; C03B 37/025 20060101 C03B037/025; C03B 37/029
20060101 C03B037/029; C03B 37/012 20060101 C03B037/012; G02B 6/02
20060101 G02B006/02; C03B 37/03 20060101 C03B037/03 |
Claims
1. A method for precoating a preform for drawing optical fiber, the
method comprising: applying a gas within a vacuum chamber housing
the preform to clean the preform; measuring, by at least one
sensor, parts per million (PPM) of a water moisture level within
the vacuum chamber; removing water from the vacuum chamber by at
least a molecular sieve and a filter membrane to maintain water
moisture level at a given range, the at least molecular sieve and
filter are within the vacuum chamber; apply, by a coating system, a
coating to a surface of the preform while the PPM of water moisture
level remains within the given range within the vacuum chamber; and
curing the coating within the vacuum chamber with an ultraviolet
light emitted from an ultraviolet lamp.
2. The method according to claim 1, further comprising maintaining
the water moisture level between approximately 0-1.5 PPM.
3. The method according to claim 1, further comprising cooling the
preform with a cooling device.
4. The method according to claim 1, wherein the coating system
comprises a plurality of coating cups to coat the optical fiber
once pulled from the preform.
5. The method according to claim 4, wherein the curing by the
ultraviolet light comprises: emitting the ultraviolet light between
adjacent coating cups of the plurality of coating cups to provide
for at least one of wet on dry coating and wet on wet coating.
6. The method according to claim 4, wherein the curing by the
ultraviolet light comprises: emitting by the ultraviolet light
after the plurality of coating cups to provide for a wet on wet
coating.
7. The method according to claim 1, wherein: the coating system
comprises at least one of a capillary subsystem and a sonic
levitation subsystem; and the method further comprising: pulling
the optical fiber from the preform; and coating the optical fiber
once pulled from the preform using the coating system.
8. The method according to claim 1, further comprising: pulling the
optical fiber from the preform; and grabbing, by a grabbing
mechanism, at least one of the preform and the pulled fiber.
9. The method according to claim 8, wherein: the grabbing mechanism
comprises a heated grabber; and the method further comprising:
heating the preform by the heated grabber to insert into the heated
preform and to initiate draw of the pulled fiber.
10. The method according to claim 9, wherein: the grabbing
mechanism comprises an electrostatic charger; and the method
further comprising: inducing an electrostatic charge at a tip of
the pulled fiber.
11. The method according to claim 1, wherein: the gas is dry
nitrogen; and the at least molecular sieve and filter membrane
filter the dry nitrogen.
12. The method according to claim 11, wherein: the vacuum chamber
is a sealed housing and includes a diameter monitor, the at least
one sensor, a preform holder to hold the preform, a draw system
with a spool for drawing the fiber, a fiber collection mechanism,
the at least molecular sieve and filter membrane filter, and an
environmental control unit; and the method further comprising:
maintaining a dry environment within the vacuum chamber by the
environmental control unit.
13. The system according to claim 11, further comprising: filtering
by the at least molecular sieve and filter membrane any outgassed
air.
14. The method according to claim 1, wherein: the gas comprises an
inert gas; and the method further comprising: controlling an oxygen
level within the vacuum chamber with the gas.
15. A method comprising: applying a gas to form a dry environment
within a sealed housing of a vacuum chamber, the vacuum chamber
including a preform holder to hold a preform from which an optical
fiber is pulled; measuring, by at least one sensor, a parts per
million (PPM) of water moisture level within the vacuum chamber;
controlling, by an environmental control unit providing a closed
system within the vacuum chamber, to maintain the dry environment
in the vacuum chamber; removing water from the vacuum chamber by at
least a molecular sieve and a filter membrane to maintain water
moisture level at a given range; coating, by a coating system, to a
surface of the fiber pulled from the preform while the PPM of water
moisture level remains within the given range; and curing the
coating.
16. The method according to claim 15, further comprising: pulling
the optical fiber from the preform; and grabbing, by a grabbing
mechanism, at least one of the preform and the pulled fiber.
17. The method according to claim 16, wherein: the grabbing
mechanism comprises a heated grabber; and the method further
comprising: heating the preform by the heated grabber to insert
into the heated preform and to initiate draw of the pulled
fiber.
18. The method according to claim 16, wherein: the grabbing
mechanism comprises an electrostatic charger; and the method
further comprising: inducing an electrostatic charge at a tip of
the pulled fiber.
19. The method according to claim 15, wherein: the gas is dry
nitrogen; and the at least molecular sieve and filter membrane
filter the dry nitrogen.
20. The method according to claim 15, wherein: the gas comprises an
inert gas; and the method further comprising: controlling an oxygen
level within the vacuum chamber with the gas.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Divisional of application Ser. No. 16/045,733
filed Jul. 25, 2018, which application claims the benefit of U.S.
Provisional Application No. 62/536,765 filed Jul. 25, 2017, the
entirety of which is incorporated by reference.
BACKGROUND
[0002] Embodiments relate to manufacture of fiber optic cable and,
more particularly to, a system and a method for manufacturing
exotic optical fiber in microgravity.
[0003] Traditionally, fiber optic draw towers are multiple meters
tall, with a total fiber path over 3 meters. This allows for fiber
to completely cool before being coated, and makes control much
easier. Further, the entire system is open, with human hands used
at multiple stages for miscellaneous tasks. Most earth-based
systems work by having the preform `dropped` after softening in the
furnace.
[0004] Exotic optical fiber, such as the Fluoride-based fiber
ZBLAN, theoretically provides 10-100 times better attenuation and
significantly broader transmission spectrum, compared to
traditional silica fiber. The term "ZBLAN" is an abbreviation based
its composition, ZrF.sub.4--BaF.sub.2--LaF.sub.3--AlF.sub.3--NaF.
ZBLAN. ZBLAN may be used to enable high performance fiber lasers,
more capable medical equipment such as laser scalpels and
endoscopes, supercontinuum light sources, more sensitive sensors
for the aerospace and defense industries, and significantly higher
bandwidth long-haul telecommunications connections. ZBLAN optical
fiber is currently produced on Earth and is sold in short lengths
for utilization in fiber lasers, such as for medical, drilling, and
image generation, supercontinuum light sources, highly-nonlinear
fibers, sensors, and other aerospace and defense applications.
Currently approximately 100 kilograms of ZBLAN optical fiber is
produced yearly. Since such low quantities is produced, the full
potential of this material has not yet been realized.
[0005] Despite the theoretical performance of ZBLAN, due to
extrinsic scattering and absorption, typical losses for
terrestrially produced ZBLAN fibers is worse than silica fiber.
Furthermore, due to these losses, terrestrially-produced ZBLAN is
useless for telecommunications applications.
[0006] Absorption losses are caused by impurities in the glass.
Scattering losses are caused by microcrystals forming in fiber as
it is pulled. There have been theoretical demonstrations showing
that crystallization is not present when fibers are formed in
microgravity. Microgravity suppresses ZBLAN crystallization,
reducing scattering loses and leading to significant performance
improvements. In other words, the unique characteristics of
microgravity enable a fundamentally superior material to be
created. Crucially, due to the short duration of microgravity on
test flights, insufficient lengths of material were produced to
quantitatively characterize these performance improvements. A
kilometer of ZBLAN fiber weighs approximately 2 kilograms. One
kilometer of ZBLAN fiber can be produced from preforms, or solid
glass rods, providing significant margin for operational costs,
amortizing the costs of ZBLAN production machinery and upmassing
and downmassing the hardware and material itself from a
microgravity environment.
[0007] The standard procedure for pulling fiber from preforms is to
begin heating the preform in the middle so that the weight of the
preform causes it to neck in the molten portion. The necking leaves
a still solid portion of preform that is then pulled from the rest
and a fiber forms between them. The drop is then cut from the fiber
and that fiber is then pulled. This method is reliant on the force
of gravity and would not work in a microgravity environment.
[0008] Once pulled, optical fibers pulled are extremely vulnerable
to damage from outside elements. To assist with this vulnerability,
fibers are coated post-pulling in polymer coatings to ensure the
fibers longevity and functionality. This process uses a pool of
melted polymer in which the fiber is run through as it is being
pulled, creating a streamlined process. For certain materials, such
as silica, this process is ideal. However, with highly sensitive
materials, such as ZBLAN, this process becomes difficult.
[0009] This difficulty arises due to ZBLAN's high sensitivity to
moisture, external contaminants, and relatively low pulling
temperature when compared to silica based fibers. ZBLAN fiber
requires an ultraclean environment void of moisture and
contaminants to be accurately produced. This makes post processing
and streamlined coating processes difficult as the entire operation
must conform to these meticulous environmental conditions.
[0010] Currently, traditional terrestrial systems are heavily
modified to operate within a zero gravity or microgravity
environment. Instead of modifying existing traditional terrestrial
systems, a system and manufacturing process specific to a
microgravity environment is desired.
[0011] Therefore, users and manufacturers of ZBLAN fiber would
benefit from a system and method which provides for a draw
operation that is performed as autonomous as possible where the
environment is controlled and a miniaturized draw tower, when
compared to prior art, is utilized.
SUMMARY
[0012] Embodiments relate to a system and a method for
manufacturing exotic optical fiber in microgravity. The system
comprises an autonomous feed system for transforming a preform into
an optical fiber that is located within an enclosure in which
environmental conditions are controlled. The autonomous feed system
comprises a preform holder, endoscopic forceps, a finance, a
plurality of pinch wheels which are autonomously controlled to
produce the optical fiber.
[0013] The method comprises removing moisture from the environment.
The method further comprises heating the preform until it is in a
viscous state. The method also comprises applying tension to an end
of the preform to cause a section of the preform to decrease in
diameter forming a neck. The method further comprising extracting a
small fiber from the neck and attaching an end of the small fiber
to a spool. The method further comprises applying a polymer layer
to the small fiber as further pulled from the neck.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A more particular description briefly stated above will be
rendered by reference to specific embodiments thereof that are
illustrated in the appended drawings. Understanding that these
drawings depict only typical embodiments and are not therefore to
be considered to be limiting of its scope, the embodiments will be
described and explained with additional specificity and detail
through the use of the accompanying drawings in which:
[0015] FIG. 1 illustrates a functional diagram of a system for
manufacturing optical fiber;
[0016] FIG. 2 illustrates another functional diagram of a system
for manufacturing optical fiber;
[0017] FIG. 3 illustrates another function diagram of a system for
manufacturing optical fiber;
[0018] FIGS. 4A-4D illustrate various views of an exemplary housing
structure for a system for manufacturing optical fiber;
[0019] FIGS. 5A-5B illustrate embodiments of a partially exposed
view of an exemplary housing structure for a system for
manufacturing optical fiber;
[0020] FIG. 6 illustrates a perspective view of an exemplary system
for manufacturing optical fiber;
[0021] FIG. 7 illustrates a perspective view of another exemplary
system for manufacturing optical fiber;
[0022] FIG. 8 illustrates another exemplary system for
manufacturing optical fiber;
[0023] FIG. 9 illustrates another embodiment of the system;
[0024] FIG. 10 illustrates an exemplary preform holder fitted to an
exemplary furnace for a system for manufacturing optical fiber;
[0025] FIG. 11 illustrates an embodiment of a micrometer;
[0026] FIGS. 12A-12C illustrate an embodiment of the furnace;
[0027] FIGS. 13A-13B illustrate further embodiments of the
furnace;
[0028] FIG. 14 illustrates an embodiment of a preform holder;
[0029] FIG. 15 illustrates an exemplary redirection assembly for
collecting fiber in a system for manufacturing optical fiber;
[0030] FIGS. 16A-16B illustrate an exemplary spooling mechanism for
collecting fiber in a system for manufacturing optical fiber;
[0031] FIG. 17 illustrates an exemplary spooling mechanism for
collecting fiber in a system for manufacturing optical fiber;
[0032] FIG. 18 illustrates an exemplary spooling mechanism with
clamp for collecting fiber in a system for manufacturing optical
fiber;
[0033] FIG. 19 illustrates an exemplary perspective view of an
exemplary system for manufacturing optical fiber with start/stop
systems shown;
[0034] FIGS. 20A-20B illustrate an exemplary pinch wheel assembly
for gripping fiber in a system for manufacturing optical fiber;
[0035] FIGS. 21A-21C illustrate an exemplary centering mechanism in
a system for manufacturing optical fiber;
[0036] FIG. 22 illustrates an exemplary fiber cutting mechanism
with waste collector in a system for manufacturing optical
fiber;
[0037] FIGS. 23A-23B illustrate an exemplary endoscope spool
mechanism in a system for manufacturing optical fiber;
[0038] FIG. 24 illustrates an exemplary gripping mechanism for
initializing draw from the preform in a system for manufacturing
optical fiber;
[0039] FIG. 25 illustrates an exemplary perspective view of an
exemplary system for manufacturing optical fiber with an exemplary
gripping mechanism highlighted;
[0040] FIGS. 26A-26B illustrate an exemplary environmental control
unit in a system for manufacturing optical fiber;
[0041] FIG. 27 illustrates an exemplary perspective view of an
exemplary system for manufacturing optical fiber with an exemplary
environmental control unit highlighted;
[0042] FIG. 28 illustrates another embodiment of the system;
[0043] FIG. 29 illustrates exemplary method steps for removing
component moisture in preparation for pre-coating a preform;
[0044] FIG. 30 illustrates exemplary method steps for assembling
fixtures in preparation for pre-coating a preform;
[0045] FIG. 31 illustrates exemplary method steps for preheating a
preform in preparation for pre-coating a preform;
[0046] FIG. 32 illustrates exemplary method steps for wrapping a
preform in a process for pre-coating a preform;
[0047] FIG. 33 illustrates an exemplary preform holder for
utilization in a process for pre-coating a preform;
[0048] FIG. 34 illustrates an exemplary heat gun application in a
process for pre-coating a preform;
[0049] FIG. 35 illustrates an exemplary avionics bay with
electronics boards of a system for manufacturing optical fiber;
[0050] FIG. 36 illustrates exemplary method steps for data flow in
a system for manufacturing optical fiber;
[0051] FIG. 37 illustrates an exemplary preform holder for a system
for manufacturing optical fiber;
[0052] FIG. 38 illustrates an alternate exemplary preform holder
for a system for manufacturing optical fiber;
[0053] FIG. 39 illustrates an alternate exemplary preform holder
for a system for manufacturing optical fiber;
[0054] FIG. 40 illustrates an alternate exemplary preform holder
for a system for manufacturing optical fiber;
[0055] FIG. 41 illustrates an alternate exemplary preform holder
for a system for manufacturing optical fiber;
[0056] FIGS. 42A-42C illustrate an exemplary redirection assembly
design for a system for manufacturing optical fiber;
[0057] FIG. 43 illustrates exemplary path variations within a
system for manufacturing optical fiber;
[0058] FIG. 44 illustrates exemplary assembled spools for a system
for manufacturing optical fiber;
[0059] FIGS. 45A-45B illustrate an exemplary spooling assembly with
redirection assembly for a system for manufacturing optical
fiber;
[0060] FIGS. 46A-46B illustrate an embodiment of assembled spools
for a system for manufacturing optical fiber;
[0061] FIG. 47 illustrates a cross sectional view of an exemplary
spool for a system for manufacturing optical fiber;
[0062] FIGS. 48A-48C illustrate exemplary capstans with various
gear designs for a system for manufacturing optical fiber;
[0063] FIGS. 49A-49D illustrate an exemplary grabbing mechanism for
a system for manufacturing optical fiber;
[0064] FIGS. 50A-50C illustrate an exemplary forceps control
assembly for a system for manufacturing optical fiber;
[0065] FIG. 51 illustrates exemplary steps for pulling fiber from a
preform for a system for manufacturing optical fiber;
[0066] FIG. 52 illustrates an exemplary alignment mechanism for
pulling fiber from a preform for a system for manufacturing optical
fiber;
[0067] FIG. 53 is an embodiment of an integrated motor and capstan
assembly for fiber spooling for a system for manufacturing optical
fiber;
[0068] FIG. 54 illustrates exemplary embodiments of forceps designs
for a system for manufacturing optical fiber;
[0069] FIG. 55 illustrates exemplary embodiments of forceps control
designs for initiating fiber draw from a preform for a system for
manufacturing optical fiber; and
[0070] FIG. 56 shows a block diagram illustrating computing
functionality of a processing system that may be used to implement
an embodiment disclosed herein.
DETAILED DESCRIPTION
[0071] Embodiments are described herein with reference to the
attached figures wherein like reference numerals are used
throughout the figures to designate similar or equivalent elements.
The figures are not drawn to scale and they are provided merely to
illustrate aspects disclosed herein. Several disclosed aspects are
described below with reference to non-limiting example applications
for illustration. It should be understood that numerous specific
details, relationships, and methods are set forth to provide a full
understanding of the embodiments disclosed herein. One having
ordinary skill in the relevant art, however, will readily recognize
that the disclosed embodiments can be practiced without one or more
of the specific details or with other methods. In other instances,
well-known structures or operations are not shown in detail to
avoid obscuring aspects disclosed herein. The embodiments are not
limited by the illustrated ordering of acts or events, as some acts
may occur in different orders and/or concurrently with other acts
or events. Furthermore, not all illustrated acts or events are
required to implement a methodology in accordance with the
embodiments.
[0072] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope are approximations, the numerical
values set forth in specific non-limiting examples are reported as
precisely as possible. Any numerical value, however, inherently
contains certain errors necessarily resulting from the standard
deviation found in their respective testing measurements. Moreover,
all ranges disclosed herein are to be understood to encompass any
and all sub-ranges subsumed therein. For example, a range of "less
than 10" can include any and all sub-ranges between (and including)
the minimum value of zero and the maximum value of 10, that is, any
and all sub-ranges having a minimum value of equal to or greater
than zero and a maximum value of equal to or less than 10, e.g., 1
to 4.
[0073] FIG. 1 illustrates a functional diagram of a system for
manufacturing optical fiber. A functional block diagram of system
100 for manufacturing optical fiber is illustrated. A series of
primary mechanisms 140-165 centrally controlled by electronic
mechanisms 105-120 may be provided. The primary mechanisms may
include, but are not limited to an environmental control unit 140,
an endoscope spool 145, a fiber spool 150, a redirection assembly
155, a furnace 160, and a preform holder 165. The control may be
based on data received from at least one sensor, though as
disclosed herein, a plurality of sensors may be provided. As shown,
a plurality of sensors 122-138 may be used. Such sensors may
include, but are not limited to an humidity sensor 122 that is
associated with the environment control unit 140, a temperature
sensor 124, a pressure sensor 126, a tension sensor 128 associated
with the fiber spool 150 and redirection assembly 155, an optical
sensor 130 also associated with the fiber spool 150 and redirection
assembly 155, an optical sensor 132 that is associated with the
redirection assembly 155, a diameter sensor 134, a temperature
sensor 136 and an accelerometer 138.
[0074] In an embodiment, the system 100 may be primarily contained
within a housing 101, wherein the manufacturing of the optical
fiber may occur within the housing 101.
[0075] Some electronic mechanisms, such as a power source 110,
controller 115, and computer MIO 120, may be located externally.
These electronic mechanisms may also be located internally, but
locating them externally may limit overheating.
[0076] The housing 101 may be hermetically sealed, wherein the
internal environment may be controlled by the internal
environmental control unit 140, which may receive sensor data about
ambient conditions, such as, but not limited to, from the humidity
sensor 122. The environmental control unit 140 may provide for a
stable and clean environment within the housing. In an embodiment,
the environment may be monitored for ambient conditions, such as,
but not limited to, through use of the temperature sensor 124 and
the pressure sensor 126. Pressure and temperature data may be
collected for reference. In an embodiment, predefined levels of the
pressure and temperature may trigger emergency actions. As a
non-limiting example, extremely high ambient temperatures may stop
the furnace 160. As a non-limiting example, a loss of pressure may
stop the system 100 in which any components that move during
operation may return to a locked or stationary position. The fiber
spool 150 may comprise a clamping mechanism 151 that may secure the
fiber to the fiber spool 150. In another embodiment, power to any
component may be disconnected. Starting and stopping the system 100
may be performed autonomously based on sensed data that is provided
to a computing functionality of a processing system that may be
used to implement an embodiment disclosed herein, as further
illustrated in FIG. 56, to operate the system 100.
[0077] A preform holder 165 may hold a plurality of preforms that
may be inserted into a furnace 160, where the preform may be heated
and fiber may be drawn from the heated preform. Preform loading and
alignment may be controlled in part by utilizing data from an
accelerometer 138.
[0078] A temperature sensor 136 may monitor the temperature within
the furnace 160. In an embodiment, multiple temperature sensors
136, such as may be provided as a sensor array, may allow for more
precise control of the temperature within the furnace 160. A
temperature profile within the furnace 160 may allow for a more
effective draw of fiber from the preform. A temperature probe 166
may be inserted into the furnace 160 between preforms, wherein the
preform holder 165 may comprise a reusable temperature probe 166.
The temperature probe 166 may comprise physical properties similar
to or the same as a preform, wherein the temperature probe 166 may
test the internal furnace conditions.
[0079] In an embodiment, an initial cutter 182 may precede the
furnace 160, wherein the initial cutter 182 may detach pulled fiber
from the remaining preform. A second cutter 174 may be located
later in the process that may detach irregular or low quality fiber
from the collectible fiber. In an embodiment, the second cutter 174
may be located proximate to a waste bin 172, which may collect the
waste fiber.
[0080] In an embodiment, pinch wheels 180 may guide forceps, not
shown, into the furnace 160 to draw fiber from the preform. The
pinch wheels 180 may guide the fiber into a diameter sensor 134
through an initial iris 178 that may center the fiber within the
diameter sensor 134. In an embodiment, a secondary iris 176 may be
located after the diameter sensor 134 that may center the fiber as
it exits the diameter sensor 134. In an embodiment, the fiber may
pass through an optical sensor 132 that may monitor the quality of
the fiber as it is drawn.
[0081] The diameter sensor 134 may be mounted under the furnace,
and is used to measure the fiber diameter as it emerges from the
furnace. This diameter sensor is used in an active control loop to
control the draw speed. If the diameter is not correct, the draw
speed is raised or lowered until the proper speed is reached to
achieve nominal diameter.
[0082] As shown in FIG. 3, a cooling system can be integrated below
the diameter sensor to rapidly cool the fiber before it is coated.
In an embodiment, an air pump or a fan may be located perpendicular
to the fiber, which cools the fiber by passing air over the fiber.
Bladeless fans could also be used to channel air along the fiber
length. In another embodiment to cool the fiber, it may also be
possible to touch the fiber with rolling pins, creating a
conductive thermal pathway from the fiber.
[0083] The fiber may also be drawn through a redirection assembly
155, which may prepare the fiber for collection. The fiber may be
pulled through a series of sensors 130, 128, such as a second
optical sensor 130 and a tension sensor 128. The tension sensor 128
may allow the system to recognize if there is a break in the fiber
and allow for control over spooling parameters by providing a
sensed data that is provided to the computing functionality of a
processing system as disclosed in FIG. 56. A fiber spool 150 may
collect the fiber, wherein the draw speed 190 may adjust based on
sensor data that is provided to the computing functionality of a
processing system. Non-limiting examples of the sensor include, but
is not limited to, the diameter sensor 134, tension sensor 128 or
combination of multiple sensors. In an embodiment, an endoscope
spool 145 may be located beyond the fiber spool 150.
[0084] FIG. 2 illustrates another functional diagram of a system
for manufacturing optical fiber. As shown the preform holder 165,
or containment device is disclosed. The preform holder 165 holds
onto multiple preforms as well as at least one temperature sensor
136. It then feeds preforms slowly into the furnace 160, providing
the necessary material for creating the fibers. The furnace 160 is
used to soften the glass preforms. The temperature may be read from
integrated sensors 136, and it is actively controlled, such as with
an active controller 210, to insure a stable thermal environment.
Thus, an active controller 210 is provided. As disclosed above, a
diameter sensor 134 or monitor is provided. A fiber tractor 220 is
provided to provide a pulling force to draw the fiber from the
preform. A coating device 230, such as, but not limited to a
pressurized coating cup 231, is provided to apply a coating to the
generated fiber. The coating device 230 may further comprise an
ultraviolet ("UV") curing lamp 232 to assist in solidifying the
applied coating. Pump sensors 233 are also shown as being provided
with the coating device 230.
[0085] Also shown are several monitors devices, or sensors,
including temperature sensors 136, relative humidity sensor 240,
video camera 242, pump sensors 233, external force sensors 244 and
diameter sensors 134. Also shown is a UV curling lamp 230 and a
nitrogen storage tank 246. This take may or may not be within the
housing 101. When not in the housing 101, a feed line is provided
through the housing 101.
[0086] As explained further herein, the drawing mechanism may
comprise at least one of a capstan, tractors, and/or spool. This
mechanism provides the pulling force necessary to draw the fiber
from the preform, as well as wind the created fiber into a compact
vessel such as, but not limited to, the spool that can then be
unwound back on Earth. These systems can be split, allowing the
fiber to travel longer distances inside the box before being
spooled. Further, several subsystems, identified as start/stop
subsystem, provide for drawing the fiber from a heated preform
without the aid of gravity, as well as being used for stopping the
drawing process in a controlled manner. The processor disclosed
herein and active controllers provides for an autonomous start/stop
system.
[0087] The tension and diameter monitors may be sensors used to
take measures of the tension in the line and the diameter of the
created fiber, respectively. Humidity, temperature, and pressure
sensors may be used to detect the parts per million (PPM) of water
content, the temperature, and the pressure inside the controlled
environment, respectfully. External Force Sensors, such as but not
limited to at least one accelerometer, may be used inside the
system to measure vibrations, which could affect fiber quality
[0088] As disclosed herein, the entire system may be held inside a
controlled environment, defined by a housing. A high purity noble
gas may be used within the housing.
[0089] Communications (or command), control data handling
(CD&H) is used to record and transmit data from the process, as
well as communicate with the automated systems.
[0090] An electronics/power subsystems are used for conditioning
power from the space station, as well as controlling all the
different subsystems.
[0091] A thermal subsystem comprises the subsystems necessary to
cool the interior and exterior of the system. Also, a structure and
mechanisms provide structure containing the environment and other
subsystems, along with necessary mechanisms to make them
function.
[0092] As a non-limiting example, the system disclosed herein
launches from Earth to the ISS in a form factor required by the
Express Rack. This structure is sealed to prevent any infiltration
of humidity into the system, and filled with a dry environment.
This environment may be maintained with a gas pump circulating air
through a HEPA filter, a carbon black filter, and molecular sieve,
or other forms of environmental control (such as pumping in fresh
nitrogen from the exterior).
[0093] The process, in summary, revolves around taking a large
diameter ZBLAN preform, heating that preform until it is in a
viscous state, then applying tension to the end of this preform.
This tension causes a section of the preform to decrease in
diameter forming a "neck." From this neck, a small fiber can be
pulled out and attached to a spool. By changing the spooling speed,
the diameter of the fiber can be controlled. Coating systems can
then apply a polymer layer to the glass, allowing it to be bent
without surface cracks breaking. Normally, gravity aids the process
by automatically allowing the neck to form, as the weight of the
bottom of the preform causes the heated preform to naturally draw
down.
[0094] FIG. 3 illustrates another function diagram of a system for
manufacturing optical fiber. As shown, a reform holder 165 is
provided. Preform material is provided to a feeder position monitor
that is provided with a feeder speed device and the preform feeder
310. The preform material is provided to the furnace 160. A
temperature sensor 136 is provided at the furnace 160. In this
embodiment a cooling device 320 is shown, hence the optical fiber
is pulled from the furnace and is feed through the cooling device.
A draw speed device 330 is provided at a capstan 330, through which
the optical fiber is pulled. A tension sensor 128 is shown to
measure tension of the optical fiber after passing through the
capstan 330. A spool speed device 340 is shown in communication
with the spool 150. A diameter sensor 134 is shown. As is also
visible, the draw speed device, feeder speed device and spool speed
device are in communication with a diameter sensor. Though not
shown, a controller may be provided to use the data collected from
the diameter sensor to establish the speed of the feeder speed
device, draw speed device and spool speed device. The ECU 140 is
also shown along with a humidity sensor and temperature sensor.
[0095] Referring now to FIGS. 4A-4D, various views of an exemplary
housing structure 101 for a system for manufacturing optical fiber
is illustrated.
[0096] Referring now to FIG. 5A-5B, embodiments of a partially
exposed view of an exemplary housing structure 101 for a system for
manufacturing optical fiber is illustrated.
[0097] Referring now to FIG. 6, a side view of an exemplary housing
structure for the system for manufacturing optical fiber is
illustrated. The structure 101 may comprise two pieces, a top
welded shell 610 with a detachable left wall 620, and a bottom
plate 630. The components disclosed herein may be mated to the top
shell 610 on an interior wall. In an embodiment, the components
disclosed herein are separated entirely. The pulling subsystems
disclosed herein may be mounted to the bottom plate 630 or ease of
assembly. The pulling assembly may be located in a hermetically
sealed, dry nitrogen environment.
[0098] Referring now to FIG. 7, a perspective view of an exemplary
system 500 for manufacturing optical fiber is illustrated. The
system 500 may comprise electronics 525 that may be located
external to the hermetically sealed housing 101. In some aspects,
the system 500 may comprise an environmental control unit 530 that
may maintain a stable and clean environment.
[0099] Referring now to FIG. 8, a perspective view of an exemplary
system for manufacturing optical fiber is illustrated. The preform
holder may comprise a revolver design that carries a temperature
sensor rod, as well as several pre-coated preforms. These are moved
into the furnace along a linear axis. From the furnace, the fiber
is led by endoscopic forceps through a diameter sensor, then
through to the spooling system. Further, the environmental control
unit and avionics bays are shown as well, the former responsible
for maintaining low humidity, the latter for containing the
electronics boards in a cooled environment. The endoscopic forceps
may be autonomously controlled by at least one controller disclosed
herein where the controller receives data from at least one sensor
of the sensors disclosed herein to provide information to allow for
autonomous operations.
[0100] As further shown in FIG. 8, the preform holder 165 may be a
solid state revolver design that carries a temperature sensor rod
136, as well as several precoated preforms. These are moved into
the furnace 160 along a linear axis. From the furnace 160, the
fiber is led by endoscopic forceps through a diameter sensor 134,
then through to the spooling system 150. Further, the environmental
control unit 140 and avionics bays are shown as well, the former
responsible for maintaining low humidity, the later for containing
the electronics boards in a cooled environment.
[0101] Referring now to FIG. 9, a perspective view of an exemplary
system for manufacturing optical fiber with pulling equipment shown
is illustrated. In some aspects, the system may comprise a preform
holder that may hold a series of preforms and at least one
temperature probe 136. In some aspects, the preform holder does not
include a temperature probe. The preform holder may alternately
insert a preform and temperature probe into the furnace 160. Fiber
may be drawn from a melted preform and directed into a diameter
sensor, such as a laser scanner that may monitor the diameter of
the drawn fiber. Once the fiber reaches a target diameter, the
subpar fiber may be disconnected and discarded into a waste
collector, and the fiber within the diameter parameters may be
guided onto a fiber redirection assembly 155, which may direct the
fiber onto a spool.
[0102] Referring now to FIG. 10, an exemplary preform holder for a
system for manufacturing optical fiber is illustrated. In some
aspects, the preform holder may comprise a revolver mounted on a
high accuracy stepper motor, which may be mounted to a linear axis.
In some embodiments, the preform holder may comprise a temperature
probe that may be inserted into the furnace between preforms, which
may ensure that the temperature profile within the furnace is
constant.
[0103] Referring now to FIG. 11, an exemplary micrometer 1201 for a
system for manufacturing optical fiber is illustrated. In some
aspects, a laser scanner, such as a high accuracy Aeroel
XLS13XY/480, may measure both diameter and concentricity. In some
implementations, such as where the system may be subjected to heavy
vibrations, the micrometer may be secured to the housing to limit
movement.
[0104] The furnace 160 is used to create the heated environment for
the preform, or preform material. This environment will decrease
the viscosity of the preform in certain sections, allowing the
preform to be drawn into fiber. The furnace 160 may be cylindrical,
with an opening at the top, or a first side, of the furnace 160
allowing for the preform to be inserted and an opening at the
bottom, or a second side, allowing for the generated fiber to be
pulled towards the spooling system.
[0105] The furnace 160 could have several possible designs. The
current baseline is a stainless steel cylindrical element with
inserted cartridge heaters, which are controlled using an active
PID loop. In an embodiment, a furnace 160 may include a hot wire or
pipe that has different modes of heating through different amounts
of wire turns in a set volume, or by utilizing radiative methods
with extremely hot localized elements.
[0106] Further, this furnace can have an installed system built in
so that ambient gas can be drawn inside, heated, and forced into
the furnace to create a temperature profile like one generated on
Earth. The air pump, fans, and parameters necessary for this are
being investigated.
[0107] Referring now to FIGS. 12A-12C, perspective views of an
exemplary furnace for a system for manufacturing optical fiber are
illustrated. In some aspects, a furnace mount 1220 may comprise
aluminum. In some embodiments, the heating element 1230 may be
positioned between two graphite insulative pads 1235, 1236, which
may keep the heating element in place while not conducting heat. In
some implementations, the iris 1240 may be mounted to the
furnace.
[0108] Referring now to FIG. 13A, an exterior view of an exemplary
furnace for a system for manufacturing optical fiber is
illustrated.
[0109] Referring now to FIG. 13B, an interior view of an exemplary
furnace 160 for a system for manufacturing optical fiber is
illustrated. The heated element 1230 is shown. As a non-limiting
example, the heated element may be made of brass or another metal
or material, such as, but not limited to a ceramic material. A tube
is shown, such as, but not limited to a quartz tube 1320, to remove
emissions from the heated element. An alignment pin and screws 1310
are also visible. A housing 1330 is shown. As a no-limiting
example, the housing 1330 may be a stainless steel jacket.
[0110] The furnace 160 may be used to heat the preform so that
fiber may be pulled from it. As a non-limiting example, the furnace
160 may comprise a stainless steel element heated by 4 cartridge
heaters and, as a non-limiting embodiment, may use a plurality,
such as, but not limited to up to 4, resistance temperature
detectors (RTDs) to use proportional-integral-derivative (PID)
control of the temperature. This element may be surrounded by a
stainless steel jacket, with air or gas, insulation between the
heated element and the outer jacket. The heated element is secured
in the jacket using either insulative pads or screws. The jacket is
then secured into a metal mount, which is bolted to the bottom
plate of the structure.
[0111] As is illustrated herein, the furnace 160 could have a
plurality of designs. In an embodiment, a stainless steel
cylindrical element with inserted cartridge heaters is provided,
which are controlled using an active PID loop. A quartz tube 1320
could also be included to ensure that emissions from the steel
element do not affect the heated preform. Another non-limiting
embodiment of the furnace 160 may include a hot wire or pipe that
has different modes of heating through different amounts of wire
turns in a set volume, or by utilizing radiative methods with
extremely hot localized elements.
[0112] In some aspects, the furnace 160 may comprise a transparent
material, wherein at least a portion of the interior of the furnace
may be visible. A visible interior may allow for a precise initial
fiber draw from the preform at a hotspot, where the preform is at a
melting point or in molten form. In some embodiments, such as in
microgravity, forceps may be inserted or touched to the surface of
the molten form to initialize the fiber draw. Utilizing a hotspot
to initialize the fiber draw may reduce loss of fiber that may
occur through other draw methods. As a non-limiting example, where
the preform may comprise a disposable tip, any portion attached to
that tip may be wasted. In some aspects, the internal topography of
the furnace 160 may be varied, wherein the variation may allow for
predefined temperature profiles within the furnace.
[0113] In an implementation, the hotspot may be determined by
directing a light source through the preform and measuring the
light as it exits the preform. A pattern may be added to the bottom
of the preform, wherein the pattern may change as the preform
melts. As the pattern changes, one or both the shadow or the light
may be distorted. The pattern may comprise an impression on the
surface of the preform or may be coated with a pattern, such as
with polytetrafluoroethylene (PTFE).
[0114] In an embodiment, forceps may draw fiber from the preform at
a predefined location within the furnace. As a non-limiting
example, one or both a temperature probe or temperature sensors may
indicate the internal temperature profile of the furnace. A target
pull location within the furnace may be based on the temperature
profile, preform material properties, and speed of preform
insertion. The initial fiber draw may draw the fiber from the
furnace into the micrometer, which may measure the diameter of the
fiber. The speed of insertion may be adjusted throughout the draw
process to reach and maintain the target fiber diameter.
[0115] In some aspects, the furnace may comprise a heating core and
an insulator portion, which may limit the heating of the ambient
environment. The insulator portion may comprise a housing and an
insulating material or mechanism. As an example, the insulator
portion may comprise circulating air. Further, this furnace can
have an installed system built in so that ambient gas can be drawn
inside, heated, and forced into the furnace to create a temperature
profile like one generated on Earth. The air pump, fans, and
parameters necessary for this are being investigated.
[0116] Over time, the interior portion of the heating core may
corrode, fiber may build up on the surface, or general damage may
occur. In some aspects, where the system may be accessible, the
heating core may be replaceable. A replaceable core may allow for
extended use of the system without requiring extensive repairs. In
some embodiments, the heating core may be replaced through
automation or manually. The replaceable heating cores may ship with
the system, wherein the heating cores may be replaced without
requiring a separate launch. The replaceable heating cores may be
launched in batches as needed or before needed, which may allow for
continuous functionality of the system.
[0117] The temperature range of the furnace may be different for
different types of preforms, such as different glass types or
coatings. In some aspects, the temperature range may be adjustable.
In some aspects, a furnace may be customized to a particular glass
type, such as ZBLAN, which has a lower melting point than other
standard optical fiber materials. In some embodiments, the heating
core or the furnace may be interchangeable, which may allow for a
change in glass type or preform size without requiring a completely
new system.
[0118] Referring now to FIG. 14, an exemplary preform holder fitted
to an exemplary furnace for a system for manufacturing optical
fiber is illustrated. In some aspects, pads (e.g., foam pads,
rubber pads) may be integrated into the side of the furnace to
contain the preforms during launch. The preforms may be contained
in these pads to prevent damage from vibration during launch
[0119] Referring now to FIG. 15, an exemplary redirection assembly
for collecting fiber in a system for manufacturing optical fiber is
illustrated. In some aspects, the redirection assembly may be a
compact version of full wheels, wherein both redirectors may move
independently. The one towards the spool may translate the fiber
during spooling and may integrate a full wheel and tension sensor.
The one towards the furnace may move to allow for waste
disposal
[0120] Referring now to FIGS. 16A-16B, an exemplary spooling
mechanism for collecting fiber in a system for manufacturing
optical fiber are illustrated. FIG. 16A shows the spool component
without an outercover. In some embodiments, the spool 150 may
comprise an embedded DC motor and gearbox 128. A passive clamp may
be used to grip fiber down to the spool. For example, RPM may be
less than 50 at all times to reduce chance of breaking the
fiber.
[0121] Referring now to FIG. 17, an exemplary spooling mechanism
for collecting fiber in a system for manufacturing optical fiber is
illustrated.
[0122] Referring now to FIG. 18, an exemplary spooling mechanism
with clamp for collecting fiber in a system for manufacturing
optical fiber is illustrated. The spool 150 may use a clamp,
springs, and a small magnet to initialize a clamp on the fiber. A
servo 1810 may move the magnet down, make contact on the clamp, and
pulling up. The fiber may be drawn under the clamp. The servo may
pull up farther, breaking the connection between the magnet and
clamp. The spring may bring the clamp down onto the fiber and pin
it.
[0123] Referring now to FIG. 19, an exemplary a perspective view of
an exemplary system for manufacturing optical fiber with start/stop
systems shown is illustrated.
[0124] The start/stop subsystem 1901 is a general name for starting
the pulling process, as well as ending it. The subsystem 1901
interfaces with a spooling subsystems extensively. The system 1901
begins the necking process of the preform as disclosed herein,
either by poking the molten end of it, or by pulling a large
section of the bottom. Once the neck is formed, the waste can be
disposed of, and a subsystem used to draw the fiber through the
entire system, eventually attaching the fiber to a spool. There can
be several different tractors, cutting assemblies, and irises used
for this process.
[0125] A grabber mechanism is provided which inserts into an
attached mount on the preform. The grabber inserts into the preform
once the preform is inserted into the hot spot, applying a constant
force to simulate 1G of gravity or the force of Earth's gravity.
The grabber may then pull the bottom chunk of material and mount
back, then cut the residual off the main fiber strand. Irises and
pinch wheels 180 then may be provided to close around the fiber
strand, inserting the fiber into a waste bin until it is the proper
size to go through the rest of the system. Endoscopic forceps
extend from behind the spool, through a clamp and two-redirection
assemblies, though a single redirection assembly may be used, and
grabs the end of a cut fiber that has been pulled from the preform.
The forceps then draw this fiber back through the system and to the
spool, where the fiber is attached. Drawing of the fiber can then
commence.
[0126] In order to stop pulling, the preform feeding is stopped,
and either the fiber is cut or allowed to break at the neck. The
spool continues to pull this loose fiber through the system, where
it is finally secured to spool for safe keeping until reentry,
bringing the fiber back to Earth for use.
[0127] Referring now to FIGS. 20A-20B, a perspective view of an
exemplary system for manufacturing optical fiber with start/stop
systems shown is illustrated. A pinch wheel assembly 180 may be
used to grip fiber and get it to desired diameter before drawing
through system. This assembly may be removed based on testing,
depending on fiber sensitivity to bending, as well as size of fiber
when drawn out of furnace. A cover 2010, as shown in FIG. 20B, may
also be provided.
[0128] Referring now to FIGS. 21A-21C, an exemplary centering
mechanism 2101 in a system for manufacturing optical fiber is
illustrated. An iris 2110 may be used to center the fiber for the
start/stop process. In some aspects, the iris 2110 may comprise a
servo and machined parts 2120 that may fit into each other as the
fiber is centered. A covering 2130, as shown in FIGS. 21B-21C, may
be provided to enclose the components associated with the iris.
[0129] Referring now to FIG. 22, an exemplary fiber cutting
mechanism 2201 with waste collector 2210 in a system for
manufacturing optical fiber is illustrated. In some aspects, a wire
cutter may be heated nichrome wire, which may cut through the
fiber. The cutting mechanism 2201 may be used to end the process,
as well as during certain parts of the start process. The waste
collector 2210 may be used to keep waste fiber and used to contain
large preform `drops.` A fan may be used to ensure all waste is
sucked to the bottom of the container.
[0130] Referring now to FIGS. 23A-23B, an exemplary endoscope spool
mechanism in a system for manufacturing optical fiber is
illustrated. An endoscopic spool may hold and control the opening
and closing of the forceps. In some aspects, the endoscopic spool
2301 may be located behind the spooling mechanism, and the
endoscopic spool 2301 may feed the forceps through the system,
where it may release the fiber onto the spooling mechanism.
[0131] Referring now to FIG. 24, an exemplary gripping mechanism
2501 for initializing draw from the preform in a system for
manufacturing optical fiber is illustrated. A gripper 2510 may be
used to insert into preattached grips on the preform. The gripper
2510 may also be referred to as a force sensor as it creates 1G of
gravity to initiate drawing the optical fiber form the preform
material. The gripper mechanism may contain a small load cell to
ensure force remains in acceptable tolerance. In some aspects, the
gripper may pierce the tip of a viscous preform, wherein pulling
the piercing may initiate a fiber draw.
[0132] Referring now to FIG. 25, a perspective view of an exemplary
system for manufacturing optical fiber with an exemplary gripping
mechanism 2501 highlighted is illustrated. The gripper 2510 can be
moved out of the way to allow for the fiber redirection assembly to
be moved into place, which may also allow for residual globs to be
added to the waste collector.
[0133] The system described herein is sealed to prevent any
infiltration of humidity and filled with a dry environment. This
environment could be maintained with a gas pump circulating air
through a high efficiency particulate air (HEPA) filter, a carbon
black filter, and molecular sieve, or other forms of environmental
control, such as pumping in fresh nitrogen from the exterior.
[0134] In some implementations, the system may comprise an
environment control unit (ECU) 140. The ECU 140 is used to maintain
the environment when the pulling operation is not occurring. The
ECU 140 utilizes filters to eliminate particles, volatiles, and
humidity from the inert gas atmosphere inside the environment. In
an embodiment, the ECU 140 may use a fan to suck air through a
filter, such as but no limited to a HEPA filter, and activated
charcoal. This air is then pushed through a molecular sieve. The
molecular sieve may have baffles to create a long path for the flow
through the sieve. Thus, the ambient environment can be completely
clean including filtering out of water.
[0135] The ECU 140 may be periodically active, such as during
operation of the furnace. In some embodiments, such as where
materials may be restocked, the system may be continuously
operating. The ECU 140 may continuously operate, may operate
periodically, or based on monitored conditions.
[0136] In some aspects, an ECU 140 may maintain the environment
according to predefined condition parameters. An ECU 140 may
comprise a filter and a fan that may draw air into the filter. The
filter may comprise one or more a HEPA filter, charcoal,
specialized ceramic, or a molecular sieve, as non-limiting
examples. In some aspects, surface area may be increased through
use of baffles or tubing. Tubing may allow the ECU 140 to be
adapted into non-standard shapes and fit between the components in
the system. The ECU 140 may comprise passive and active components.
For example, the fan may draw air through the ECU 140 when the
system is active, such as when the furnace is on or fiber is being
spooled. The ECU 140 may passively filter the air when the system
is not in operation and a separate circulation device, such as a
fan, may be collecting debris from a prior fiber draw.
[0137] In some embodiments, the ECU 140 may be replaceable, such as
where the system is accessible. Where the system may be opened and
accessed, the ECU 140 may be periodically replaced manually or
through automation. In some aspects, the environment may be large
enough to include an automation system that may replace consumable
and damaged components. The ECU 140 may not be activated until the
system is in use or at least until the system is sealed. For
example, the ECU 140 may periodically run while the system is in
storage to maintain the environment within the predefined
parameters.
[0138] In some aspects, the ECU 140 may be engaged during the
assembly process, wherein the ECU 140 may initiate the purging of
the system, as the housing is hermetically sealed. The system may
be over-pressured and under-pressured to effectively purge the
environment. One or more the system or its components, such as, but
not limited to, the filter, molecular sieve, pump or fan and an
inner or internal surface of the ECU 140 housing, may be baked
until they are effectively outgassed. The entire system may be
flushed with nitrogen gas, helium, or other gas to control the
oxygen levels. In some aspects, where the system is flushed with an
inert gas, at least a portion of the assembly may occur within an
inert gas environment. In some aspects, the components or preforms
may be pretreated before assembly, such as with methanol.
[0139] In some embodiments, an ECU 140 may comprise a cooling
mechanism that may supplement general airflow mechanisms in the
case of emergencies. For example, in the event of a failure, there
may be a need to quickly lower temperature to prevent fiber from
sticking to walls of the furnace or other parts within the box. If
the furnace overheats, a cooling mechanism may reduce damage from
furnace failure.
[0140] More particularly, referring now to FIGS. 26A-26B, an
exemplary environmental control unit in a system for manufacturing
optical fiber is illustrated. In some aspects, an ECU 140 may
comprise a compact rectangular package 2701, or housing, but with
the incorporation of baffles, can still give a long residence time
of the air with the sieve 2720. It can be used with either a high
throughput fan, or a higher pressure pump. It incorporates both a
charcoal filter 2710 and HEPA filter 2712. Note that these filters
will be the first to touch the flow, so that only clean, slow, and
uniform airflow touches the molecular sieve 2720. Moreover, these
filters can clean the interior of anything outgassed during a pull.
In some embodiments, the ECU may have integrated humidity sensors.
The ECU 140 may communicate with sensors located throughout the
system, such as sensors for temperature, pressure, or
contamination.
[0141] Thus, as shown, activated charcoal filters 2710 (or carbon
black filters) and HEPA filters 2712 are located in order to
cleanse the air from any contaminants. Then, a molecular sieve 2720
is contained in a series of meshes and baffles, which dehumidifies
the air or dry the air to the single PPM range. This subsystem is
used both before unit operation, to dry any residual humidity from
the environment during a bake out, and between operations to filter
any outgassed air.
[0142] Other configurations than the box configuration can be used,
such as, but not limited to a cylindrical configurations and a tube
configuration. Thus, form factor of the unit to change based on
what is needed for the flight system.
[0143] The molecular sieve 2720 may be contained in a series of
meshes and baffles, which dehumidifies the air. The molecular sieve
2720 may dry the air to the single PPM range. This subsystem may be
used both before unit operation, to dry any residual humidity from
the environment during a bake out, and between operations to filter
any outgassed air. Configurations other than the box configuration
may be used, including, for example, cylindrical configurations
tube shaped systems. These allow the form factor of the unit to
change based on what is needed for the flight system.
[0144] In some implementations, scrubbing/cleaning a gas
environment of moisture may enhance the manufacturability of fiber
optic materials in a contained environment. In some aspects,
drawing (pulling)/pushing the environmental fluid through a filter
membrane then through a molecular sieve then back to the
environment may be autonomous and inherent to the closed system. By
using a closed system, it ensures environmental quality of the
fluid, thus limiting the chance for imperfections/defects in the
manufacture in the fiber optic material. The system operates by
sensing the humidity in the environment and then turning on when it
becomes greater than the set desired level. The manufacturing
environment may be isolated from external environmental
elements.
[0145] Referring now to FIG. 27, a perspective view of an exemplary
system for manufacturing optical fiber with an exemplary
environmental control unit highlighted is illustrated.
[0146] FIG. 28 is another embodiment of the system. As shown, the
system comprises the ECU 140, the spool, a redirection assembly, a
waste water disposal container. A cutting device, a micrometer,
pinch wheels, the furnace, the preform holder and the endoscopic
forceps.
[0147] A method provides for scrubbing/cleaning a gas environment
of moisture, water, to enhance the manufacturability of fiber optic
materials in a contained environment. This method utilizes a method
of drawing(pulling)/pushing the environmental fluid through a
filter membrane then through a molecular sieve then back to the
environment. This method is autonomous and inherent to the closed
system. By using a closed system, it ensures environmental quality
of the fluid, thus limiting the chance for imperfections/defects in
the manufacture in the fiber optic material. They system operates
by sensing the humidity in the environment and then turning on when
it becomes greater than the set desired level. The manufacturing
environment will be isolated from external environmental
elements.
[0148] Thus, the method comprises sensing humidity in the
environment, where an optical fiber is being manufactured, with a
sensor. The method further comprises relaying the sensed data to a
controller. The method also comprises drawing environmental fluid
through a filter membrane then through a molecular sieve then back
to the environment with at least one of a fan and a pump based on
the sensed data to control environmental conditions where the
optical fiber is being manufactured as controlled by the
controller.
[0149] The method may also comprise comprising accelerating flow
reduction to a lower temperature with a cooling mechanism. Also,
the method may comprise outgassing at least one of the filter, the
molecular sieve, at least one of the pump and the fan and an
internal surface of the housing with a heater.
[0150] Referring now to FIG. 29, exemplary method steps for
removing component moisture in preparation for pre-coating a
preform are illustrated. The method 2900 may comprise the
components that may be cleaned of all oils and contaminates using
the proper solvent/cleaner for the material, at 2910. The
components may be placed in the vacuum chamber of the glovebox and
open the vacuum valve, at 2920. As a non-limiting example, the
components may be left in the chamber for 30 minutes to an hour, at
2930. The chamber may be filled with clean dry nitrogen at 2930.
The steps in the glovebox may be repeated, at step 2950, and the
components may be transferred into the glove box with the
environmental atmosphere being circulated through a molecular
sieve, at step 2960.
[0151] Referring now to FIG. 30, exemplary method steps for
assembling fixtures in preparation for pre-coating a preform are
illustrated. The method 3000 comprises the components that may be
vacuumed, at step 3010, and then assembled, at step 3020. The
preform may be gripped, at step 3030, so that approximately .5
inches (8 mm), plus or minus a quarter of an inch, is being gripped
by a collet. The preform may be placed in the center of the
assembly, at step 3040, so that if spun the preform remains as
concentric as possible. Tightening may be performed, at 3050, so
that the collet grips the preform, wherein not to over tighten
limitations are provided. In an embodiment, hand tight is fine. The
concentricity of the preform may be verified, at step 3060, by
turning the assembly and observing the preform.
[0152] Referring now to FIG. 31, exemplary method steps for
preheating a preform in preparation for pre-coating a preform are
illustrated. The water content of the glove box may be confirmed
for <1PPM water content, at step 3110. The motor, which may be a
stepper motor, such as but not limited to a NEMA 17 motor, may be
mounted, at step 3120, approximately 8-10 inches, plus or minus one
inch, vertically in an area a heat gun freely may be freely
manually manipulated. Though a heat gun is disclosed, other heat
producing or generating sources may be used. Therefore, a heat gun
is non-limiting. The preform holder may be slid with the ZBLAN
preform onto the shaft of the motor, at step 3130, and turn the
motor on to a desired speed, such as but not limited to 30 RPM. A
heat gun may be provided and set at a desired temperature, at step
3140, such as, but not limited to approximately 300.degree. F.
(149.degree. C.), plus or minus five degrees, at a low fan setting,
which may be placed on the floor of the glovebox so that it is not
blowing on or near the preform and up. The glovebox atmosphere may
reach a steady state, at 3150. During this time, pressure and
moisture content in the glovebox will rise and may be monitored
closely, relieving pressure when applicable. The glovebox may
remain like this until the moisture level is less than 1 PPM
water.
[0153] The heat gun may start a distance away from the preform
traversing back and forth at approximately 1 inch (25 mm), plus or
minus half an inch for approximately 2 minutes, plus or minus a
minute, at step 3160, wherein a non-limiting example of distance
may be approximately 8 inches, plus or minus two inches. The heat
gun may move closer, at step 3170, such as but not limited to
approximately one inch, to the preform repeating the above process
until a given distance away, such as, but not limited to
approximately three inches (76 mm), plus or minus one inch, from
the preform is achieved. The preform is removed from the holder
assembly, at step 3180.
[0154] Referring now to FIG. 32 exemplary method steps for wrapping
a preform in a process for pre-coating a preform are illustrated.
During this process, 3200, the PPM of water moisture level inside
the glove box may be between approximately 0-1.5 PPM, plus or minus
0.25 PPM. If it raises above this level, the process may be shut
down until it falls below 1 PPM before restarting. The heat gun may
reach the appropriate temperature, at step 3210, keeping the fan
speed at the lowest setting. A Type K thermocouple or equivalent
may be used to test the temperature of the heat gun approximately
2.5 inches (63 mm), plus or minus 0.5 inches, from the nozzle.
Verify it is within .+-.10.degree. of the desired temperature. If
the temperature is not within the appropriate range adjust the heat
gun's temperature accordingly until the proper temperature is
achieved.
[0155] The preform may be removed from the holder assembly, at step
3215. The preform may be inserted into a piece of shrink tubing
.about.1.5'' (38 mm) longer than the preform, at step 3220, so
there is an equal amount of tubing on either end. The wrapped
preform assembly may be held approximately 3 inches (76 mm), plus
or minus one inch, above the heat gun, wherein the overhanging
tubing may slightly shrink, at step 3225. The excess tubing may be
removed from the shrunk end, at step 3230. The newly cut end may be
placed in the holder, at step 3235, and the holder may be placed on
the motor, at step 3240.
[0156] The heat gun may be aimed at the free end of the wrapped
preform at a 45.degree.-60.degree. angle from the rotational axis
(see FIG. 34). The heat gun may be moved back and forth over a
0.5'' (13 mm) length until the tubing has shrunk which for PTFE
tubing will turn clear then shrink, at step 3245.
[0157] The preform may cool, at step 3250, to less than
approximately 200.degree. F. (93.degree. C.), plus or minus ten
degrees and then may be removed from the assembly and flipped
around, at step 3255, where the other side may be shrink-wrapped.
The preform may be examined for bubbles, at step 3260, if any
appear hold the heat gun over that area moving back and forth as
before. Once completed, the preform may be cooled to ambient, at
step 3265, and the excess tubing may be cut from the wrapped
preform, at step 3270.
[0158] Referring now to FIG. 33, an exemplary preform holder for
utilization in a process for pre-coating a preform is illustrated.
A preform material extends from the preform holder 3301. A clamp
3310 is provided to hold the preform material. Also shown is a
guide rod 3320 and engagement threads 3330 which are used to secure
the clamp 3310.
[0159] Referring now to FIG. 34, an exemplary heat gun application
in a process for pre-coating a preform heat gun is illustrated. As
shown a heat gun 3401, is applying heat to a preform, a preform
material, or a material rod. A coating 3410 is shown as being
around the preform material.
[0160] Referring now to FIG. 35, an exemplary avionics bay with
electronics boards of a system for manufacturing optical fiber is
illustrated.
[0161] Referring now to FIG. 36, exemplary method steps for data
flow in a system for manufacturing optical fiber is illustrated.
The fiber optic production facility is referred to as "MISFO." In
some aspects, a portion of the steps may occur manually prior to
launch or may be omitted. Software may perform tasks throughout the
process, and installation may occur manually. Collection of the
fiber and data after retrieval may occur manually and through use
of software.
[0162] Referring now to FIG. 37, an exemplary preform holder for a
system for manufacturing optical fiber is illustrated. The preform
holder 165 may include a rotatable revolver piece 3701 with
preforms secured using stainless steel clamps 3710. The revolver
may be turned using a highly accurate stepper motor, and translated
using a linear rail with attached stepper. In some aspects, homing
sensors may be used to ensure knowledge of position and autonomous
operation.
[0163] Once a preform is aligned with the top of the furnace 160,
it may be moved through the furnace 160 using the rail 3720. It may
be fed at a set rate, feeding new material into the hot spot of the
furnace so that new fiber can be pulled.
[0164] Thus, it may rotate a solid revolver piece, with preforms
secured using stainless steel clamps. The revolver is turned using
a highly accurate stepper motor, and translated using a linear rail
with attached stepper. Homing sensors may be used to ensure
knowledge of position and autonomous operation. Once a preform is
aligned with the top of the furnace, it is moved through the
furnace using the rail. It is fed at a set rate, feeding new
material into the hot spot of the furnace so that new fiber can be
pulled.
[0165] Referring now to FIG. 38, another exemplary preform holder
for a system for manufacturing optical fiber is illustrated. In
some aspects, the preform may comprise a trident 3810, which may
hold multiple cantilevered preforms in a linear stepper on a
traversal. The preforms may be gripped in chucks mounted to a
backboard 3820. The backboard 3820 may be translated forward to
feed the current preform into the furnace 160. Once the preform
feed is complete, the residual preform is retracted and the next
preform translated into an aligned position with the furnace 160.
In another embodiment, the linear stepper is mounted on a
traversal. Two actuators may be needed.
[0166] Referring now to FIG. 39, an alternate exemplary preform
holder 165 for a system for manufacturing optical fiber is
illustrated, wherein the preform holder comprises a solid-state
revolver 3701. With a linear rail and a rotary actuator 3720, the
preform holder 165 may support multiple preforms. Similarly to the
trident example, the preform holder is not deformed or changed, but
remains "solid-state." Here, instead of a trident design, the
preforms may be mounted to a revolver. The system may translate
forward to feed a preform into the furnace. Once the preform feed
is completed the residual is retracted, and a new preform moved
into place by revolving the entire backboard.
[0167] Referring now to FIG. 40, another embodiment of a preform
holder for a system for manufacturing optical fiber is illustrated.
Using a guide rail 3720 to the furnace 160, a linear actuator, a
rotary actuator, and a `screw or bolt` actuator, may increase the
amount of preforms used. Here, the preforms may be mounted to a
revolver which can rotate. However, the preforms may be removed
from their mounts, and translated separately using the linear axis.
This may free up space on the revolver 3701 for increasing the
number of preforms.
[0168] Referring now to FIG. 41, another embodiment of a preform
holder for a system for manufacturing optical fiber is illustrated.
Using a guide rail 3720 to the furnace 160, 2 linear actuators, and
a `screw or bolt` actuator may increase the amount of preforms
used. Similar to the revolver embodiments, except instead of a
revolver driven by stepper and the preforms being removed from the
revolver with a translation device, the preforms are fed in using a
`clip`-like system, where preforms are stored on a rail, and then
translated using a linear actuator or spring into a feed position.
Once they are in this position, the preforms can be moved into the
furnace using a linear axis. This concept allows for the most
efficient preform packing, but is complex.
[0169] The preform containment and feed system may be provided with
different concepts for holding multiple preforms. One may use a
solid-state revolver to hold the preforms in a circular
configuration, while others may utilize different magazine designs
that use springs or motors to move preforms into position.
[0170] In one embodiment, the preforms is mounted on two linear
rails in a trident position. The preforms are gripped in chucks
mounted to a backboard. The backboard is translated forward to feed
the current preform into the furnace. Once the preform feed is
complete, the residual preform is retracted and the next preform
translated into an aligned position with the furnace.
[0171] Similar to the trident example, in that the preform holder
is not deformed or changed, but remains "solid-state" instead of a
trident design, the preform may be mounted to a revolver. The
system can translate forward to feed a preform into the furnace.
Once the preform feed is completed the residual is retracted, and a
new preform moved into place by revolving the entire backboard.
This is both less complex than the next two methods listed and
space saving over the trident example.
[0172] In another embodiment, the preforms are mounted to a
revolver 3701 which can rotate. However, the preforms can be
removed from their mounts, and translated separately using the
linear axis. This is similar to a bullet being fed to a chamber
from a revolving magazine. This frees up space on the revolver for
increasing the number of preforms.
[0173] Similar to the embodiment immediately above, instead of a
revolver driven by stepper and the preforms being removed from the
revolver with a translation device, the preforms are fed in using a
`clip` like system, where preforms are stored on a rail, and then
translated using a linear actuator or spring into a feed position.
Once they are in this position, that can be moved into the furnace
using a linear axis. This concept allows for the most efficient
preform packing, but is complex.
[0174] In the creation of an autonomous fiber pulling device the
ability to redirect delicate fibers is critical. When the assembly
needs to shrink due to limited area for a system, the pulley wheel
takes up considerable volume. To save volume several small pulleys
can be arranged so that their surfaces are tangent to the surface
of the larger pulley. The fiber can then take the direction change
resting on several pulleys that take up considerably less volume
than the equivalent single large pully. Surrounding the pulleys is
a guide path that allows an endoscope like mechanism to be pushed
through the pulley assembly and then retracted with a fiber
attached so that the fiber only contacts the metal bearings and no
other surface.
[0175] Referring now to FIGS. 42A-42C, an exemplary redirection
assembly design for a system for manufacturing optical fiber is
illustrated. It is arranged onto rails, enabling them to be moved,
both to change the fiber feed path onto the spool, and to enable it
to be moved into position once the start/stop process is
initiated.
[0176] In the creation of an autonomous fiber pulling device,
redirection of delicate fibers is essential. Surrounding the
pulleys is a guide path that allows an endoscope-like mechanism to
be pushed through the pulley assembly and then retracted with a
fiber attached so that the fiber only contacts the metal bearings
and no other surface.
[0177] Referring now to FIG. 42B, an exemplary cutaway displaying
the interior of the fiber redirection assembly is shown. Metal
bearings may be used to redirect the fiber without the need for a
large wheel or pulley.
[0178] Referring now to FIG. 42C, an exemplary portion of the fiber
redirection system is shown. Note that all edges can be rounded and
funnels added to insure the fiber is center.
[0179] Referring now to FIG. 43, exemplary path variations within a
system for manufacturing optical fiber are illustrated. In some
aspects, these may be lined up at slight angles, so that the fiber
path could be increased to larger and larger lengths if required.
This distance allows the fiber time to cool, and allows the spool
to mount in different configurations. The left shows using a wheel,
the center using a fiber redirection assembly, and the right
showing the ability to customize the path as needed using either
method. Note that many of these can be lined up at slight angles,
so that the fiber path could be increased to larger and larger
lengths if required. The allows the fiber time to cool, or allows
the spool to mounted in different configurations, as shown
below.
[0180] Referring now to FIG. 44, an exemplary spooling assembly for
a system for manufacturing optical fiber is illustrated. A large
spool 4401 responsible for housing as well as opening and closing
the endoscopic forceps 4410 is shown on the far left. A stepper
motor may be used to push the endoscope through the system. An
attached optical sensor 4420 may be used to ensure the endoscope
remains in the correct positions. The spool 150 incorporates a
gearbox and DC motor, which drives the spool to the correct RPM
based on input from the micrometer.
[0181] In some embodiments, a DC motor may be used to control the
revolutions per minute ("RPM") of the spool, while the fiber is fed
from the furnace (not shown) through the two fiber redirection
assemblies to spool. The fiber redirector closest to the spool may
be translated on a linear axis, allowing the fiber to be translated
on the spool. This enables the fiber to be laid down onto the spool
properly, giving efficient and safe packing of the material.
[0182] Referring now to FIGS. 45A-45B, an exemplary spooling
assembly with redirection assembly for a system for manufacturing
optical fiber is illustrated.
[0183] Referring now to FIG. 45A, an exemplary view of the spooling
assembly from the top is shown. The linear axis (the black piece)
is mounted to the top of the box. It allows the left fiber
redirection assembly to move, which can move the fiber to different
places on the spool (shown in green). It allows the left fiber
redirection assembly to move, which can move the fiber to
difference places on the spool.
[0184] Referring now to FIG. 45B, an exemplary view of the assembly
from the bottom is shown. The fiber redirection assemblies are
shown in red; the spool is shown in green. The spool is driven by a
DC motor, the fiber can be attached to the spool by using an
endoscope like device, shown later. A linear axis may be mounted to
a top of the box.
[0185] An embodiment uses a DC motor to control the RPM of the
spool (shown as green in the picture), while the fiber is fed from
the furnace (not shown) through the two fiber redirection
assemblies to spool. The fiber redirector closest to the spool is
translated on a linear axis, allowing the fiber to be translated on
the spool. This enables the fiber to be laid down onto the spool
properly, giving efficient and safe packing of the material.
[0186] Referring now to FIGS. 46A-46B, exemplary assembled spools
for a system for manufacturing optical fiber are illustrated.
[0187] Referring now to FIG. 46A, an exemplary assembled spool
without backplate is shown. Note the green is the surface that
holds the generated ZBLAN fiber, while the black box is the DC
motor and gearbox.
[0188] Referring now to FIG. 46B, an exemplary spool interior is
shown. In some embodiments, there may be a motors housing 4615 and
two bearings 4620.
[0189] Referring now to FIG. 47, a cross sectional view of an
exemplary spool for a system for manufacturing optical fiber is
illustrated. When directly driven, the capstan and motor may be
concentric with a plate on one end of the capstan extending to the
center where it is connected to the motor. The motor may be held
fixed with structures extending out the other side of the capstan
opposite of the drive shaft. The side to side actuation is
performed by linear actuators and rails mounted around the capstan
and the slides are connected to the motor structure. This spool may
be driven by a DC motor. If the motor requires a gearbox, that can
also be placed into the interior of the spool.
[0190] Referring now to FIGS. 48A-48C, exemplary capstans with
various gear designs for a system for manufacturing optical fiber
is illustrated. In some embodiments, the gear design may comprise
an asymmetric planetary gear. The gear driven design 4801 allows
for compaction of the actuation components and linear rail inside
the capstan instead of outside it. This can help reduce the size
considerably. The capstan 4810 is driven by a planetary style gear
system. This leaves room free between the gears that allow linear
rails to feed through. The planetary gear can either be symmetric
with the motor centered on the axis or Asymmetric with the motor
not centered on the capstan. Either works but when integrating the
actuator motor into the same space the Asymmetric can allow for
more internal room for a given capstan diameter.
[0191] The tractor, spooling, and capstan system can be provided in
a plurality of embodiments. Different stepper motors and DC motors
may be used to apply tension onto the preform material. Once
combined with heat, this tension on the preform draws it into a
fiber. By changing the speed of the DC motors and accompanying
spool, the diameter of the fiber can be changed. A fiber tractor
may be used before the spool, in order to pull fiber without
spooling it, while a large spool spun by motor can apply the main
drawing force. By directly changing the rotation speed of the
spool, the fiber diameter can be controlled, while by moving the
spool or a turning wheel in front of the spool, the fiber can be
layered in a set pattern.
[0192] A tension sensor may be integrated into the redirection
assembly. This sensor, by measuring tension in the line, can help
to ensure that the fiber is being drawn with the correct settings
to ensure a stable pull.
[0193] Referring now to FIGS. 49A-49D, an exemplary grabbing
mechanism for a system for manufacturing optical fiber is
illustrated. This mechanism is designed to grab onto both glass
preforms and glass fiber. A DC motor fixed into a cylindrical
barrel actuates a tab with a lead screw to apply the grasping
force. The barrel 4910 may be mounted into a bearing 4920, allowing
it to rotate by a fixed secondary motor 4930. Using this rotational
degree of freedom, the same grabber 4950 may be used to either grab
a preform or a fiber. Further, this rotation allows for the
mechanism to guide the fiber around redirection wheels and around
other mechanisms.
[0194] In an embodiment, the grabber 4950 may comprise a secondary
heater, wherein a heated grabber may insert into a heated preform
to initiate draw of the fiber. In some embodiments, an
electrostatic charge may be induced at the tip of the drawn fiber,
and the draw system may comprise electrostatically driven pathway,
wherein the fiber may be directed through the system through
driving a charge through the pathway.
[0195] Referring now to FIGS. 50A-50C, an exemplary forceps control
assembly for a system for manufacturing optical fiber is
illustrated. In an embodiment, a compact assembly may extend and
retract an endoscope like device, and mechanically control any
mechanism embedded in it. The assembly may provide autonomous
control within a compact volume. The forceps/endoscope may be wound
around a spool 5010 with the mechanical mechanisms 5020 to control
any attachments at the end integrated into the spool. By
integrating them into the spool, it reduces a large amount of
excess forceps/endoscope that would be wasted as a twisting buffer
between the rotating spool and a fixed actuation mechanism. The
spool is spring wound to retract the forceps. Before leaving the
assembly, the forceps are routed through a motor module that uses a
drive wheel/gear and pinch wheel/gear 5030 to drive the
forceps/endoscopes forward and backwards. The spring winding of the
spool keeps the forceps wrapped neatly around the spool always with
one end of the forceps held in position by the motor module.
[0196] Referring now to FIG. 51, exemplary steps for pulling fiber
from a preform for a system for manufacturing optical fiber are
illustrated. Fiber formation is done using some form of forceps or
needle 5110 to grab onto the partially melted preform to then pull
the fiber through fiber pulling assembly 5120 (usually includes
redirection pulleys and an optical micrometer) where it is attached
to a spool that then pulls the remaining majority of fiber. The
forceps/needle mechanism 5110 is fed through the fiber spool and
remaining components of the assembly until it reaches the preform
in the furnace. Once there it attaches to the melting glob,
retracts and forms the fiber to be pulled through the assembly and
attached to fiber spool.
[0197] The current prior art method of fiber drawing involves the
use of a person for grabbing the preform drop, cutting and
attaching the fiber to a spool. Embodiments disclosed herein are
for the automation of that process to a degree that an assembly can
be supplied solely with the fiber preforms and output a fully wound
spool of fiber without human interaction with the preform or fiber
within the assembly. This has uses in the creation of small scale
and entirely autonomous manufacturing of fiber. Thus, embodiments
may be used to create specialty fibers in the environment of outer
space where an autonomous assembly greatly reduces the cost
compared to requiring a person to spend only a few seconds
beginning and ending a process that can then run autonomously for
significant periods of time. Fiber formation may be done using a
forceps or needle to grab onto the partially melted preform to then
pull the fiber through fiber pulling assembly (usually includes
redirection pulleys and an optical micrometer) where it is attached
to a spool that then pulls the remaining majority of fiber. The
forceps/needle mechanism is fed through the fiber spool and
remaining components of the assembly until it reaches the preform
in the furnace. Once there it attaches to the melting glob,
retracts and forms the fiber to be pulled through the assembly and
attached to fiber spool.
[0198] Referring now to FIG. 52, an exemplary alignment mechanism
for pulling fiber from a preform for a system for manufacturing
optical fiber is illustrated. When using forceps for gripping
objects, floating in air alignment is quite important, especially
when done robotically. This is a simple ring 5210 constructed of
electromagnets and an optically based means of determining the
position of the forceps 5110. The magnets 5220 are energized
specifically to draw the forceps 5110 to specific positions which
would align the forceps to whatever target desired without
requiring a tight guide tube in that specific area. A similar ring
5210 can also be constructed that uses either electrostatic forces
or small puffs of air to create the same outcome.
[0199] The prior art procedure for pulling fiber from preforms is
to begin heating the preform in the middle so that the weight of
the preform causes it to neck in the molten portion. The necking
leaves a still solid portion of preform that is then pulled from
the rest and a fiber forms between them. The drop is then cut from
the fiber and that fiber is then pulled. This method is reliant on
the force of gravity and would not work in a microgravity
environment.
[0200] As disclosed herein as shown a method provides for melting a
very tip of the preform to create a semi molten globule. The method
further provides for either grabbing by forceps or stabbing with a
needle the tip of the preform. The method further comprising
pulling a fiber from the glob with the at least one of forceps and
needle. The first fiber pulled can then be used to pull the rest of
the preform into fiber. This method not only produces less waste
but can be utilized in both a gravitational and non-gravitational
environment, which is important for manufacturing in space.
[0201] Referring now to FIG. 53, an exemplary compact integrated
motor and capstan assembly for fiber spooling for a system for
manufacturing optical fiber is illustrated. The purpose of this
design is to reduce the amount of unused space when driving a
capstan for spooling fiber. This is of specific concern when volume
is at a premium such as pulling fiber optics in space. The
following are variants of the same idea for integrating a motor
within the empty space of a capstan and allowing the capstan
assembly to actuate side to side. The capstan is essentially a
hollow pipe with lips on the outside and large thin form bearings
on the inside to spin freely around a motor and other objects
placed inside.
[0202] As shown in FIG. 53, various variations of a device that is
passed through various path intended for the pulling of fiber. This
path includes the preform passing through the furnace 160. This
device has a head comprising of a gripper or a spear or an
interface that allows it to attach itself to either the fiber or
the base material from which the fiber is formed. Once the device
has attached itself it can then transition the fiber or material
through the original path for the purpose of spooling or
transitioning it to another stage of manufacture. The path may
include passing by a pully and/or through a guide. As further
shown, there may be a starting position and an eventual ending
position.
[0203] Referring now to FIG. 54, exemplary embodiments of forceps
designs for a system for manufacturing optical fiber is
illustrated. In some aspects, a device may have the added ability
to encapsulate a fiber within the device itself. This may lead to a
separate manufacturing stage, waste recovery from miss manufacture,
temporary holding during transition stages. This ability is
inherent to the device and may separate it from the rest of the
environment in an intermittent, temporary or permanent fashion.
This device may be actuated in a similar manner to linkage cables
for shifting a car or activating an endoscope, there is an inner
section that translates independently of the outer section. It is
this relative motion that allows for the changing relationship to
its environment and grants it the ability to isolate itself. As
further shown in FIG. 54, the gripper or forceps are able to grab
the fiber. As is also shown, the gripper may have a plurality of
different ends which engage the fiber.
[0204] Thus, as shown in FIG. 54, the device, gripper or forceps,
may comprise various inner geometries dependent of the grip type
desired, such as circular, toothed, recessed, or shaped to a
specific profile. The device may be directly attached to an inner
member that is also in the housing and is used to physically push
or pull the device relative to the housing dictation the opening
and closing feature. This direct physical movement may be due
through mechanical connection, a piston pushing a fluid (e.g.,
water, oil, or air), or the application of a stored energy force,
releasing a compressed or stretched spring, as non-limiting
examples. This device may be used to isolate the inner housing from
the environment, pressure/temperature carrying fluid (e.g., oil,
coolant, or air) or used to contain a desired element/material from
the environment.
[0205] In another embodiment, the device may be actuated with an
electrical for and/or an outside mechanical force.
[0206] Referring now to FIG. 55, exemplary embodiments of forceps
control designs for initiating fiber draw from a preform for a
system for manufacturing optical fiber is illustrated. In some
embodiments, a device may be actuated open and closed in different
configurations, wherein the configurations may allow it to apply
varying or set amounts of force for the purpose of gripping,
attaching, compressing, expanding itself to a material that can
produce a fiber type material or a fiber itself. The device may be
actuated by translation through a housing that
compresses/constrains the device. The device may be energized due
to this compression the housing implements when the device is
translated through it. This may allow the holding action the device
can give to the material. The device can consist of a single
member/coil or many finger type implements or coils.
[0207] In some implementations, a tube member 5510 that has a head
attachment may attach itself to the material then pull the fiber
along a specified path to a spooling system. The head attachment
may release the material and the material may be spooled, or the
material may be grabbed by the spooling mechanism and the fiber may
then release from the tube member either by actuating it or by
breaking the fiber from the head of the tube member by using the
spooling mechanism. This method may utilize the tube mechanism to
perform maintenance work if the fiber breaks, becomes stuck, or to
clear the system and reset it to pull fiber again minimizing down
time, as non-limiting examples.
[0208] In some embodiments, a stored energy device may limit
centralization issues with regards to locating the fiber. This
method may use a device that when it releases opens to an area that
encompasses the fiber and then is activated allowing the device to
surround and close around the fiber. This may trap or grab the
fiber and then the device can effectively pull the fiber into a
commercial fiber optic quality fiber.
[0209] A flowchart illustrating a method of pulling fiber optic
grade material autonomously, without manipulation that is not
inherent to the manufacturing system, or without human/outside
intervention may be provided. This method comprises attaching a
tube member that has a head attachment to a material to be pulled.
The method also comprises pulling the material along a specified
path to a spooling system. The method further comprises releasing
the material as it is spooled on a spooling mechanism.
[0210] The method may further comprise grabbing the material with
the spooling mechanism to spool the material on the spooling
system. The method may further comprise releasing the material from
the tube member by at least one of actuating the tube member and
breaking the fiber from the head of the tube member by using the
spooling mechanism. This method can also utilize the tube mechanism
to perform maintenance work if the fiber breaks, becomes stuck,
etc., to clear the system and reset it to pull fiber again
minimizing down time.
[0211] A method for gripping fiber utilizing a stored energy device
that eliminates centralization issues with regards to locating the
fiber is also possible. This method uses a device that when
releases it opens to an area that encompasses the fiber and then is
activated allowing the device to surround and close around the
fiber. This traps/grabs the fiber and then the device can
effectively pull the fiber into a commercial fiber optic quality
fiber.
[0212] Another method for sealing an enclosed environment from
external elements is disclosed. The method provides for a system of
pressurized channels that will act as a barrier between an enclosed
volume and the external environment. This system will consist of
two or more sealing elements that have a void or barrier separating
them. This barrier will be pressurized with an inert gas or fluid
that will isolate the internal environment from the external one.
This helps contain the enclosed volume as well as mitigates
contamination issues the external environment may cause to the
internal volume. It can be used in manufacture of materials needing
ultra clean atmospheres. This may be accomplished by directing
diffusion in a specified manner from the high pressure area in
between the seals to both the internal and external environment.
This controlled diffusion protects the clean internal environment
from external contaminants as well as prolonging the time the
environment can remain viable as clean.
[0213] The method may also be supplemented by an internal
compressor that pressurizes the zone in between the two or more
seals, creating a self-maintaining system. This method may also use
a vacuum in between the sealing elements. The sealing elements
themselves may have external support to help energize them,
pressure applied to then via fluid or gas, squeeze due to the
enclosure, spring type element to push against the seal,
friction/press fit of seal in specified channel, spring imbedded to
seal to self-energize it, mechanical load inputted to the seal, any
method of energizing the seal really. A vacuum is then pulled in
between the sealing system to limit diffusion between the external
and internal environments. Any combination of the pressurized and
vacuum seal concepts, with metal, mechanical, elastomeric,
non-elastomeric polymer, thermoplastic, thermoset, composite, or
other type of seal.
[0214] In some implementations, an enclosed environment may be
sealed from external elements utilizing a system of pressurized
channels that may act as a barrier between an enclosed volume and
the external environment. This system may consist of two or more
sealing elements that have a void or barrier separating them. This
barrier may be pressurized with an inert gas or fluid that will
isolate the internal environment from the external one. The barrier
may help contain the enclosed volume as well as mitigates
contamination issues the external environment may cause to the
internal volume. The system may be used in manufacture of materials
needing ultra clean atmospheres, such as by directing diffusion in
a specified manner from the high pressure area in between the seals
to both the internal and external environment. Controlled diffusion
may protect the clean internal environment from external
contaminants as well as prolonging the time the environment can
remain viable as clean.
[0215] This This method may also be supplemented by an internal
compressor that re-pressurizes the zone in between the two or more
seals, creating a self-maintaining system. This method may also use
a vacuum between the sealing elements. The sealing elements
themselves may have external support to help energize them, such as
pressure applied to then via fluid or gas, squeeze due to the
enclosure, spring type element to push against the seal,
friction/press fit of seal in specified channel, spring embedded to
seal to self-energize it, mechanical load inputted to the seal, or
other methods of energizing the seal. A vacuum may pull between the
sealing system to limit diffusion between the external and internal
environments. In some aspects, the method may utilize a combination
of the pressurized and vacuum seal concepts, with metal,
mechanical, elastomeric, non-elastomeric polymer, thermoplastic,
thermoset, composite, or other type of seal.
[0216] FIG. 56 shows a block diagram illustrating computing
functionality of a processing system that may be used to implement
an embodiment disclosed herein. The methods provided in the
embodiments disclosed above may be used in association with the
computing functionality 1000 disclosed below to provide for real
time monitoring and feedback in the deposition process. Multiple
sensors may provide data that is used by correction applications
provided herein with respect to the methods disclosed herein where
control may be provided.
[0217] In all cases, computing functionality 1000 represents one or
more physical and tangible processing mechanisms. The computing
functionality 1000 may comprise volatile and non-volatile memory,
such as random-access memory (RAM) 1002 and read only memory
("ROM") 1004, as well as one or more processing devices 1006 (e.g.,
one or more central processing units (CPUs), one or more graphical
processing units (Gus), and the like). The computing functionality
1000 also optionally comprises various media devices 1008, such as
a hard disk module, an optical disk module, and so forth. The
computing functionality 1000 may perform various operations
identified above when the processing device(s) 1006 execute(s)
instructions that are maintained by memory (e.g., RAM 1002, ROM
1004, and the like).
[0218] Instructions and other information may be stored on any
computer readable medium 610, including, but not limited to, static
memory storage devices, magnetic storage devices, and optical
storage devices. The term "computer readable medium" also
encompasses plural storage devices. In all cases, computer readable
medium 1010 represents some form of physical and tangible entity.
By way of example, and not limitation, the computer readable medium
610 may comprise "computer storage media" and "communications
media."
[0219] "Computer storage media" comprises volatile and
non-volatile, removable and non-removable media implemented in any
method or technology for storage of information, such as computer
readable instructions, data structures, program modules, or other
data. The computer storage media may be, for example, and not
limitation, RAM 1002, ROM 1004, EPSOM, Flash memory, or other
memory technology, CD-ROM, digital versatile disks (DVD), or other
optical storage, magnetic cassettes, magnetic tape, magnetic disk
storage, or other magnetic storage devices, or any other medium
which can be used to store the desired information and which can be
accessed by a computer.
[0220] "Communication media" typically comprise computer readable
instructions, data structures, program modules, or other data in a
modulated data signal, such as carrier wave or other transport
mechanism. The communication media may also comprise any
information delivery media. The term "modulated data signal" means
a signal that has one or more of its characteristics set or changed
in such a manner as to encode information in the signal. By way of
example, and not limitation, communication media comprises wired
media such as a wired network or direct-wired connection, and
wireless media such as acoustic, FRO, infrared, and other wireless
media. Combinations of any of the above are also included within
the scope of computer readable medium.
[0221] The computing functionality 1000 may also comprise an
input/output module 1012 for receiving various inputs (via input
modules 1014), and for providing various outputs (via one or more
output modules). One particular output module mechanism may be a
presentation module 1016 and an associated graphic user interface
("GUI") 1018. The computing functionality 1000 may also include one
or more network interfaces 1020 for exchanging data with other
devices via one or more communication conduits 1022. In some
embodiments, one or more communication buses 1024 communicatively
couple the above-described components together.
[0222] The communication conduit(s) 1022 may be implemented in any
manner (e.g., by a local area network, a wide area network (e.g.,
the Internet), and the like, or any combination thereof). The
communication conduit(s) 1022 may include any combination of
hardwired links, wireless links, routers, gateway functionality,
name servers, and the like, governed by any protocol or combination
of protocols.
[0223] Alternatively, or in addition, any of the functions
described herein may be performed, at least in part, by one or more
hardware logic components. For example, without limitation,
illustrative types of hardware logic components that may be used
include Field-programmable Gate Arrays (Fogs), Application-specific
Integrated Circuits (Asics), Application-specific Standard Products
(Asps), System-on-a-chip systems (Sacs), Complex Programmable Logic
Devices (Colds), and the like.
[0224] The terms "module" and "component" as used herein generally
represent software, firmware, hardware, or combinations thereof. In
the case of a software implementation, the module or component
represents program code that performs specified tasks when executed
on a processor. The program code may be stored in one or more
computer readable memory devices, otherwise known as non-transitory
devices. The features of the embodiments described herein are
platform-independent, meaning that the techniques can be
implemented on a variety of commercial computing platforms having a
variety of processors (e.g., set-top box, desktop, laptop,
notebook, tablet computer, personal digital assistant (PDA), mobile
telephone, smart telephone, gaming console, wearable device, an
Internet-of-Things device, and the like).
[0225] Thus, as discussed above, the system is sealed to prevent
any infiltration of humidity and filled with a dry environment.
This environment could be maintained with a gas pump circulating
air through a high efficiency particulate air (HEPA) filter, a
carbon black filter, and molecular sieve, or other forms of
environmental control, such as pumping in fresh nitrogen from the
exterior.
[0226] As disclosed above, the system may be housed in a
hermetically sealed box, which may limit access to the system
components. In some aspects, the seal may comprise multiple sealing
mechanisms, such as an elastomeric seal between two portions of the
housing and a vacuum seal between seal materials. For example, the
system may be configured to fit into an express rack of the
International Space Station or may be self-sustaining in a
free-flying spacecraft. The space limitations of an express rack
may limit production to a single run of the preforms stored and
shipped in a preform holder. For a free-flying spacecraft, the
system may comprise mechanisms to reload, restock, or repair
components or consumable materials. In some embodiments, the system
may allow for limited or full access to the components. For
example, a portion of the housing may be removed to allow manual
access to repair, replace, or restock components or consumable
materials. As another non-limiting example, access may be limited
to restocking consumable materials, such as preforms and spooling
materials; removing deliverables, such as spools of optical fiber;
and removing excess waste from a waste collector.
[0227] The process may initiate by utilizing a large diameter
preform, heating the preform until it is in a viscous state, then
applying tension to the end of the preform. This tension may cause
a section of the preform to decrease in diameter forming a "neck."
From this neck, a small fiber may be pulled out and attached to a
spool. By changing the spooling speed, the diameter of the fiber
may be controlled. Coating systems may apply a polymer layer to the
glass, allowing it to be bent without surface cracks breaking. In
standard gravity conditions, gravity aids the process by
automatically allowing the neck to form, as the weight of the
bottom of the preform causes the heated preform to naturally draw
down. In microgravity, the effect of gravity is negligible, and the
drawing process may be automated.
[0228] The preform containment and feed system also holds a
temperature probe containing multiple temperature sensors. This
probe may be used to map the thermal environment of the furnace, as
well simulate the heat up of a preform. This may be particularly
significant in microgravity where a thermal environment may be
different than in standard gravity conditions. In some embodiments,
conductive heat profiles may be simulated in microgravity through
use of fans.
[0229] The preform containment and feed system may be used to grip
a preform, which may then be moved from the cooler ambient
environment to the interior of the furnace. The furnace may heat
the preform to the correct temperature, and the start/stop
subsystem may draw fiber from the heated preform. This system may
ensure that the preforms survive the launch process using several
foam protective sleeves, into which the preforms are inserted
during launch. Accelerometers may be attached to the preform holder
to monitor the vibrations of the preform during drawing.
[0230] The furnace is used to create the heated environment for the
preform. This environment will decrease the viscosity of the
preform in certain sections, allowing the preform to be drawn into
fiber. The furnace is cylindrical, with an opening at the top of
the furnace allowing for the preform to be inserted and an opening
at the bottom allowing for the generated fiber to be pulled towards
the spooling system.
[0231] The furnace is used to create the heated environment for the
preform. This environment will decrease the viscosity of the
preform in certain sections, allowing the preform to be drawn into
fiber. The furnace is cylindrical, with an opening at the top of
the furnace allowing for the preform to be inserted and an opening
at the bottom allowing for the generated fiber to be pulled towards
the spooling system.
[0232] The start/stop subsystem is the general name for starting
the pulling process, as well as ending it. The subsystem interfaces
with spooling subsystems extensively. The system begins the necking
process of the preform, either by poking the molten end of it, or
by pulling a large section of the bottom. Once the neck is formed,
the waste can be disposed of, and a subsystem used to draw the
fiber through the entire system, eventually attaching the fiber to
a spool. There can be several different tractors, cutting
assemblies, and irises used for this process.
[0233] The current design has a grabber mechanism which inserts
into an attached mount on the preform. The grabber inserts into the
preform once the preform is inserted into the hot spot, applying a
constant force to simulate 1G of gravity. The grabber then pulls
the bottom chunk of material and mount back, then cut the residual
off the main fiber strand. Irises and pinch wheels then close
around the fiber strand, inserting the fiber into a waste bin until
it is the proper size to go through the rest of the system.
Endoscopic forceps extend from behind the spool, through a clamp
and 2 redirection assemblies, and grab the end of a cut fiber that
has been pulled from the preform. The forceps then draw this fiber
back through the system and to the spool, where the fiber is
attached. Drawing of the fiber can then commence.
[0234] In order to stop pulling, the preform feeding may stop, and
the fiber may be cut or allowed to break at the neck. The spool may
continue to pull this loose fiber through the system, where it may
be secured to spool and stored until reentry. In some aspects,
debris and discarded fiber may be drawn into or placed into a waste
collector.
[0235] A diameter sensor is mounted under the furnace, and is used
to measure the fiber diameter as it emerges from out of the
furnace. This diameter sensor is used in an active control loop to
control the draw speed. If the diameter is not correct, the draw
speed is raised or lowered until the proper speed is reached to
achieve nominal diameter.
[0236] The tractor, spooling, and capstan system has a large amount
of design freedom. Different stepper motors and DC motors can be
used to apply tension onto the preform. Once combined with heat,
this tension on the preform draws it into a fiber. By changing the
speed of the DC motors and accompanying spool, the diameter of the
fiber can be changed. A fiber tractor can be used before the spool,
in order to pull fiber without spooling it, while a large spool
spun by motor can apply the main drawing force. By directly
changing the rotation speed of the spool, the fiber diameter can be
controlled, while by moving the spool or a turning wheel in front
of the spool, the fiber can be layered in a set pattern.
[0237] A tension sensor is integrated into the redirection
assembly. This sensor, by measuring tension in the line, can help
to ensure that the fiber is being drawn with the correct settings
to ensure a stable pull. In some embodiments, a portion of the
electrical components may be external to the controlled
environment. In some aspects, potted bulkhead fittings may allow
for an electrical pass through with limited exposure to
contaminants.
[0238] An ECU is used to maintain the environment when the pulling
operation is not occurring. This utilizes filters to eliminate
particles, volatiles, and humidity from the inert gas atmosphere
inside the environment. The current baseline uses a fan to suck air
through a HEPA filter and activated charcoal. This air is then
pushed through molecular sieve, with baffles creating a long path
for the flow through the sieve. Thus, the ambient environment can
be completely clean and filter water. Temperature and pressure
sensors located in the environment to ensure that it remains in any
specified or required tolerances. A humidity sensor monitors water
content inside the volume.
[0239] In some aspects, a preform holder may comprise a solid-state
revolver configuration, wherein the preform holder may rotate
preforms and at least one temperature probe. In some embodiments,
the preform holder may comprise a magazine design, wherein a new
preform moves into place once the previous preform is discarded. In
some magazine configurations, a separate temperature probe
mechanism may allow for the insertion of a reusable temperature
probe independent of the magazine design. In some aspects,
disposable temperature probes may be integrated into the magazine,
wherein the temperature probe debris may be guided into the waste
collector.
[0240] In some aspects, the waste collector may comprise a fan,
which may draw air and debris into the waste collector or direct
air to create a barrier to limit the loss of debris, as
non-limiting examples. The waste collector may comprise directional
bristles that may limit escape of debris, such as in microgravity
conditions. In some embodiments, the waste collector may extend the
length of the furnace, wherein preform waste may be collected
before and after the furnace. For example, after the furnace, the
collected fiber may be trimmed of portions that do not fall into
the collectible fiber parameters, and before the furnace, preform
stubs may be ejected from the preform holder.
[0241] In some aspects, the waste collector may collect other
unsecured debris, which may result from damage to the system or
breakage of the fiber during collection. The debris may be directed
into the waste collector through an integrated airflow system,
which may comprise a series of vents and ducting that may be
embedded in the base or walls of the housing. The airflow system
may allow for efficient circulation of air within the environment
and for directed airflow, such as may direct floating debris into
the waste collector.
[0242] The subsystem may comprise several different embodiments for
holding multiple preforms. One uses a solid-state revolver to hold
the preforms in a circular configuration, while others utilize
different magazine designs that use springs or motors to move
preforms into position.
[0243] In some aspects, the preform may comprise a starter tip that
may facilitate the initial fiber draw from the preform. The tip may
comprise a vacuum-sealed tip, wherein a plastic grip may be
attached to the end of a preform. A grabber may engage the plastic
directly or may engage a tip embedded in the plastic, such as a
hook or loop. Once the draw is initiated, the tip may be detached
by a cutter after the furnace. In some embodiments, the starter tip
may be ground from the end of the preform. For example, the end of
the preform may comprise notches that the grabber may latch onto.
In some aspects, preforms may be manufactured in microgravity. For
example, manufacturing preforms and the optical fiber in low Earth
orbit may allow for faster delivery of additional preforms.
[0244] Further, the data from any one of the sensors disclosed
above may be provided to the computing functionality 1000 to
determine at least placement of the dispenser 142, 210 where the
processor and a processor executable instructions are stored on the
tangible storage medium to receive a measurement from the first
sensor to determine a height of the deposition system from the
build location.
[0245] Thus, as provided above, the system described herein is
sealed to prevent any infiltration of humidity and filled with a
dry environment. This environment could be maintained with a gas
pump circulating air through a high efficiency particulate air
(HEPA) filter, a carbon black filter, and molecular sieve, or other
forms of environmental control, such as pumping in fresh nitrogen
from the exterior.
[0246] An embodiment provides for coating the preform from which
the fiber is drawn. This method pulls the fiber and coating as one
unit as the fiber is being produced. In some embodiments, ZBLAN
preforms may be wrapped in heat shrink tubing. In some
implementations, different materials may be wrapped using a similar
process.
[0247] In some aspects, a cooling system may be integrated below
the diameter sensor to rapidly cool the fiber before it is coated.
In an embodiment, use of air pumps or fans located perpendicular to
fiber, which cool the fiber through passing air over it may be
applied. Bladeless fans may be used to channel air along the fiber
length. It may also be possible to touch the fiber with rolling
pins, creating a conductive thermal pathway from the fiber.
[0248] The coating system has several approaches. For one, it may
not be needed at all, as certain grades of Teflon or other polymers
can be pre-applied and melted onto the preform. Using traditional
coating methods such as pressurized dies could also provide the
necessary coating when combined with UV curing lamps. In some
aspects, using pressurized sprays of material may coat the fiber in
a limited amount of space.
[0249] In some aspects, the fiber may be drawn through coating cups
that may coat the fiber in one or more coating materials and then
pass through curing lamps. Other methods for applying coating may
include capillary action or sonic levitation. The curing lamps may
be located between the coating cups, which may allow for wet or dry
coating or wet on wet coating, or the curing lamps may be located
after the final coating cup, which may limit the coating to wet on
wet. In some aspects, coatings may be customizable, wherein the
coating materials may be integrated based on the particularly
demands of a project.
[0250] In some aspects, the system may comprise a diameter sensor,
which may be positioned after the furnace. The diameter sensor may
monitor the diameter of drawn fiber as it is drawn from the
preform. In some embodiments, a plurality of diameter sensors may
monitor diameter of the drawn fiber throughout the manufacturing
process. For example, such as where the furnace comprises a
transparent portion, a first diameter sensor may monitor the
diameter of the fiber at a location proximate to the initial draw
point. A second diameter sensor may monitor the diameter the fiber
as it exits the furnace. A third diameter sensor may be located at
another point in the system, wherein the third diameter sensor may
monitor the fiber for additional quality control.
[0251] Where a preform may be precoated, the diameter sensor may
base the measurements from surface data. For example, a micrometer
may comprise a laser that may determine concentricity and diameter.
Without the coating, the fiber may be transparent, and the diameter
sensor may utilize surface data and internal data, such as to
monitor clarity of the fiber.
[0252] In some embodiments, the system may comprise tension
sensors, which may be monitor tension of the fiber being pulled by
the forceps. A sudden loss in tension may indicate a break, and a
building increase in tension may precede a break. The monitored
data may prompt an action by a system component. For example, a
break may stop the fiber draw and prompt a change to the next
preform. A break may also prompt fans to direct any floating debris
to the waste collector.
[0253] In some aspects, some sensors may be active during
transportation of the system, wherein the active sensors may
monitor conditions for threshold levels, which may adversely affect
the system. Accelerometers may be active during a launch to monitor
threshold vibration levels that may cause damage to the system,
such as damaging the preforms or causing the subsystem to fall out
of alignment with the furnace or spool, as non-limiting examples.
In some aspects, environmental sensors may be periodically
activated to ensure the conditions stay within predefined
parameters.
[0254] For example, temperature and humidity sensors may activate
every ten days while the system is stored in an open warehouse. The
data may be transmitted when the sensors are activated or the data
may be accessed at logistic checkpoints. For example, the humidity
data may be accessed prior to launch, wherein there may be an
opportunity to retreat the system, such as flushing the environment
with nitrogen. Accessing sensor data prior to installation or
launch may limit installation or launch of damaged systems.
[0255] In some implementations, the system may comprise a gantry
system, which may allow for more precise manipulation of components
within the system. The system may comprise sensors that may monitor
for damage to a component or the housing. A repair arm on the
gantry system may be equipped to repair holes or cuts. For example,
it may add an epoxy or monomer then apply a curing mechanism, such
as exposure to UV or heat. As another example, the arm may weld
small holes. In some aspects, the system may comprise a
contamination sensor, and the repair arm may expose the section to
UV to kill living contaminants.
[0256] In some aspects, the spooling mechanism may comprise an
internal motor, wherein the spool may spin around the motor. In
some embodiments, the spool portion may be removable and
replaceable. For example, once full, the spool portion may be
removed and transported in that spool. In some implementations, the
fiber may be transferred to a secondary spool, which may be less
expensive or more efficient.
[0257] Where the spool may be replaceable, the system may be
shipped or launched with a batch of spools. For example, where the
system is accessible, the spools may be replaced manually or
through automation. In some aspects, full spools may be removed and
stored for shipment within the system, such as in a free-flying
spacecraft. Where spools may be stored and/or shipped separately,
they may be collapsible or able to be assembled. A spool may
comprise three flat pieces that connect or fit into each other to
form the spool. In some aspects, the spool may be printed onsite,
which may allow for local manufacturing of the spools on
demand.
[0258] The spool may comprise a catching mechanism that may secure
a fiber end to the spool. In some aspects, the catching mechanism
may comprise a grip that may be magnetically or spring-driven. For
example, the grip may be triggered once a predefined amount fiber
is in contact with the spool. As another example, the grip may be
triggered based on a predefined amount of pressure applied by one
or both the forceps and the fiber. A still further example, the
grip may be triggered by a control mechanism.
[0259] In some aspects, the surface of the spool may comprise a
passive gripping material or surface. Optical fiber may be
delicate, particularly during the initial spooling stage, which may
wrap at the low diameter, and catching methods may account for this
fragility. For example, the spool may comprise a friction lock or a
v-catch that may engage the fiber as it is spooled. As another
example, the surface of the spool may comprise a sticky material,
such as a soft rubber, wax paper, epoxy, or tape. The sticky
material may be inherent to the spool surface or may be applied
when the fiber is spooled. For example, a piece of double-sided
tape may be adhered to the portion of the spool that the fiber may
wind around. The pieces of tape may be precut or cut from a
tape-dispensing unit. Where the system may be intended for extended
use with restockable materials, tape embodiments may be practical
and easily and inexpensively restocked.
[0260] Temperature and pressure sensors are located in the
environment to ensure that it remains in the specified tolerances
as required any space launch agency or company, such as, but not
limited to NASA. A humidity sensor monitors water content inside
the volume. Finally, accelerometers can be attached to the preform
holder to monitor the vibrations of the preform during drawing.
[0261] An alternate option is to coat the preform from which the
fiber is drawn. This method pulls the fiber and coating as one unit
as the fiber is being produced. In some embodiments, ZBLAN preforms
may be wrapped in heat shrink tubing. In some implementations,
different materials may be wrapped using a similar process.
[0262] In some aspects, a cooling system may be integrated below
the diameter sensor to rapidly cool the fiber before it is coated.
Current designs use air pumps or fans located perpendicular to
fiber, which cool the fiber through passing air over it. Bladeless
fans may be used to channel air along the fiber length. It may also
be possible to touch the fiber with rolling pins, creating a
conductive thermal pathway from the fiber.
[0263] The coating system has several approaches. For one, it may
not be needed at all, as certain grades of Teflon or other polymers
can be preapplied and melted onto the preform. Using traditional
coating methods such as pressurized dies could also provide the
necessary coating when combined with UV curing lamps. In some
aspects, using pressurized sprays of material may coat the fiber in
a limited amount of space.
[0264] In some aspects, the fiber may be drawn through coating cups
that may coat the fiber in one or more coating materials and then
pass through curing lamps. Other methods for applying coating may
include capillary action or sonic levitation. The curing lamps may
be located between the coating cups, which may allow for wet on dry
coating or wet on wet coating, or the curing lamps may be located
after the final coating cup, which may limit the coating to wet on
wet. In some aspects, coatings may be customizable, wherein the
coating materials may be integrated based on the particularly
demands of a project.
[0265] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting. As
used herein, the singular forms "a," "an," and "the" are intended
to include the plural forms as well, unless the context clearly
indicates otherwise. Furthermore, to the extent that the terms
"including," "includes," "having," "has," "with," or variants
thereof are used in either the detailed description and/or the
claims, such terms are intended to be inclusive in a manner similar
to the term "comprising." Moreover, unless specifically stated, any
use of the terms first, second, etc., does not denote any order or
importance, but rather the terms first, second, etc., are used to
distinguish one element from another.
[0266] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which embodiments
of the invention belongs. It will be further understood that terms,
such as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and will not be
interpreted in an idealized or overly formal sense unless expressly
so defined herein.
[0267] While various disclosed embodiments have been described
above, it should be understood that they have been presented by way
of example only, and not limitation. Numerous changes, omissions
and/or additions to the subject matter disclosed herein can be made
in accordance with the embodiments disclosed herein without
departing from the spirit or scope of the embodiments. Also,
equivalents may be substituted for elements thereof without
departing from the spirit and scope of the embodiments. In
addition, while a particular feature may have been disclosed with
respect to only one of several implementations, such feature may be
combined with one or more other features of the other
implementations as may be desired and advantageous for any given or
particular application. Furthermore, many modifications may be made
to adapt a particular situation or material to the teachings of the
embodiments without departing from the scope thereof.
[0268] Further, the purpose of the foregoing Abstract is to enable
the U.S. Patent and Trademark Office and the public generally and
especially the scientists, engineers and practitioners in the
relevant art(s) who are not familiar with patent or legal terms or
phraseology, to determine quickly from a cursory inspection the
nature and essence of this technical disclosure. The Abstract is
not intended to be limiting as to the scope of the present
disclosure in any way.
[0269] Therefore, the breadth and scope of the subject matter
provided herein should not be limited by any of the above
explicitly described embodiments. Rather, the scope of the
embodiments should be defined in accordance with the following
claims and their equivalents.
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