US20120040105A1 - Method and Apparatus Providing Increased UVLED Intensity and Uniform Curing of Optical-Fiber Coatings - Google Patents

Method and Apparatus Providing Increased UVLED Intensity and Uniform Curing of Optical-Fiber Coatings Download PDF

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US20120040105A1
US20120040105A1 US13/206,601 US201113206601A US2012040105A1 US 20120040105 A1 US20120040105 A1 US 20120040105A1 US 201113206601 A US201113206601 A US 201113206601A US 2012040105 A1 US2012040105 A1 US 2012040105A1
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uvled
array
source
sources
output intensity
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Bob J. Overton
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Draka Comteq BV
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Draka Comteq BV
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Priority to US15/229,286 priority patent/US10029942B2/en
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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/62—Surface treatment of fibres or filaments made from glass, minerals or slags by application of electric or wave energy; by particle radiation or ion implantation
    • C03C25/6206—Electromagnetic waves
    • C03C25/6226—Ultraviolet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065—After-treatment
    • B05D3/067—Curing or cross-linking the coating
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/12—General methods of coating; Devices therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2203/00—Other substrates
    • B05D2203/30—Other inorganic substrates, e.g. ceramics, silicon
    • B05D2203/35—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2256/00—Wires or fibres

Definitions

  • the present invention embraces an apparatus and a method for curing coatings on drawn glass fibers.
  • Glass fibers are often protected from external forces with one or more coating layers.
  • two or more layers of coatings are applied during the optical-fiber drawing process (i.e., whereby a glass fiber is drawn from an optical preform in a drawing tower).
  • a softer inner coating layer typically helps to protect the glass fiber from microbending.
  • a harder outer coating layer typically is used to provide additional protection and to facilitate handling of the glass fiber.
  • the coating layers may be cured, for example, using heat or ultraviolet (UV) light.
  • UV curing requires that the coated glass fiber be exposed to high intensity UV radiation. Curing time can be reduced by exposing the coating to higher intensity UV radiation. Reducing curing time is particularly desirable to permit an increase in fiber drawing line speeds and thus optical-fiber production rates.
  • Mercury lamps e.g., high-pressure mercury lamps or mercury xenon lamps
  • mercury lamps are commonly used to generate the UV radiation needed for UV curing.
  • One downside of using mercury lamps is that mercury lamps require a significant amount of power to generate sufficiently intense UV radiation.
  • UV lamps used to cure a single coated fiber i.e., one polymeric coating
  • mercury lamps Another shortcoming of mercury lamps is that much of the energy used for powering mercury lamps is emitted not as UV radiation but rather as heat. Accordingly, mercury lamps must be cooled (e.g., using a heat exchanger) to prevent overheating. In addition, the undesirable heat generated by the mercury lamps may slow the rate at which the optical-fiber coatings cure.
  • mercury lamps generate a wide spectrum of electromagnetic radiation, such as electromagnetic radiation having wavelengths of less than 200 nanometers and greater than 700 nanometers (i.e., infrared light).
  • electromagnetic radiation having wavelengths of less than 200 nanometers and greater than 700 nanometers (i.e., infrared light).
  • UV radiation having wavelengths of between about 300 nanometers and 400 nanometers is useful for curing UV coatings.
  • glass fibers typically possess a diameter of about 125 microns or less, which, of course, is much smaller than the mercury bulbs. Consequently, most of the UV radiation emitted by the mercury lamps does not reach the glass fiber's uncured coating (i.e., the energy is wasted).
  • UVLEDs to cure glass-fiber coatings as an alternative to conventional mercury lamps. UVLEDs typically require significantly less energy and correspondingly generate much less heat energy than conventional UV lamps.
  • U.S. Pat. No. 7,022,382 discloses the use of UV lasers (e.g., continuous or pulsed lasers) for curing optical-fiber coatings.
  • UV lasers e.g., continuous or pulsed lasers
  • U.S. Patent Application Publication No. 2003/0026919 discloses the use of ultraviolet light emitting diodes (UVLEDs) for curing optical-fiber coatings.
  • UVLEDs ultraviolet light emitting diodes
  • the present invention embraces a UVLED apparatus for curing in situ optical-fiber coatings (i.e., on a glass fiber).
  • An exemplary apparatus for curing a coated glass fiber includes a cavity that defines a curing axis.
  • a first UVLED array is positioned within the cavity.
  • the first UVLED array includes a plurality of UVLED sources, each of which has (or is otherwise configured to have) a variable (e.g., oscillating) output x n (t) of UV radiation having a maximum output intensity x n (t) max and a minimum output intensity x n (t) min .
  • the maximum output intensity x n (t) max of each of the UVLED sources is greater than can be achieved by driving each UVLED source at its respective maximum rated current.
  • at least two of the UVLED sources have oscillating outputs of UV radiation that are out of phase with one another.
  • the apparatus includes a controller that is capable of adjusting the intensity and/or phase of the oscillating outputs of the UVLED sources.
  • the present invention embraces a method of curing a coating on a glass fiber.
  • a glass fiber having an incompletely cured coating is passed at a line speed v f through a cavity and along a curing axis that is defined by the cavity.
  • a plurality of UVLEDs that define a first UVLED array are driven at a current that is greater than the maximum rated current of the UVLED sources.
  • Each UVLED source has an oscillating output x n (t) of UV radiation having a maximum output intensity x n (t) max and a minimum output intensity x n (t) min .
  • the maximum output intensity x n (t) max of each of the UVLED sources is typically greater than could be achieved if each UVLED source was driven at its maximum rated current.
  • UV radiation from the first UVLED array is emitted (e.g., into the cavity) to promote the curing of the glass-fiber coating.
  • the first UVLED array typically defines a normalized sum x total (t,v f ):
  • FIG. 1 schematically depicts an exemplary apparatus for curing a coated glass fiber according to one aspect of the present invention.
  • FIGS. 2 a - 2 d schematically depict exemplary UVLED source output waveforms.
  • FIG. 3 schematically depicts a perspective view of an exemplary apparatus for curing a coated glass fiber according to another aspect of the present invention.
  • FIG. 4 schematically depicts a cross-sectional view of an exemplary apparatus for curing a coated glass fiber according to an aspect of the present invention.
  • FIG. 5 schematically depicts the relationship between UVLED emission angle and UVLED efficiency for UVLEDs of various widths.
  • FIG. 6 schematically depicts a cross-sectional view of an exemplary apparatus for curing a coated glass fiber according to yet another aspect of the present invention.
  • the present invention embraces an apparatus for curing glass-fiber coatings (e.g., primary coatings, secondary coatings, and/or tertiary ink layers).
  • the apparatus typically employs one or more UVLED arrays.
  • each UVLED array has a plurality of UVLED sources that are capable of being driven beyond their normal operating current (e.g., overdriven beyond a UVLED source's maximum rated current).
  • the apparatus 10 for curing glass-fiber coatings includes a UVLED array 11 a (denoted by a dotted circle) positioned within a cavity 12 (e.g., a substantially cylindrical cavity).
  • a cavity 12 e.g., a substantially cylindrical cavity.
  • the interior of the cavity 12 defines a curing space.
  • the curing space defines a curing axis 13 along which a drawn glass fiber passes during the curing process.
  • the UVLED array 11 a includes a plurality of UVLED sources 14 a .
  • a mounting plate 15 may be employed to provide structural support for the UVLED sources 14 a .
  • FIG. 1 depicts the UVLED array 11 a having two UVLED sources 14 a .
  • each UVLED source is formed from a single light emitting diode. That said, it is within the scope of the present invention to employ a plurality of small light emitting diodes to form each UVLED source.
  • each UVLED source (e.g., a single UVLED or a plurality of discrete UVLEDs) is overdriven to achieve a higher-than-normal output intensity.
  • each UVLED source is typically driven at a higher-than-rated power and current (e.g., higher than its normal operating current) so that each UVLED source has a maximum output intensity that is greater than could be achieved using a UVLED source's maximum rated current.
  • a UVLED source may be driven at a current 2-4 times its maximum rated current (e.g., three times its maximum rated current). For some UVLED sources, a three-fold increase in current results in up to an eight-fold increase in UV-radiation output intensity.
  • a device's maximum rated current is the maximum current that the device can continuously carry, while remaining within its temperature rating.
  • each UVLED source is typically driven at a higher-than-rated current, each UVLED source is typically driven at its normal operating voltage.
  • the cure rate of an optical-fiber coating depends not only on the total UV radiation dosage but also on the intensity of the UV radiation to which the coating is exposed. As will be appreciated by those having ordinary skill in the art, it has been observed that an increase in the intensity of UV radiation results in a nonlinear (e.g., squared) increase in the cure rate of a coating. By overdriving UVLED sources, the cure rate of optical-fiber coatings can be increased, thereby enabling higher line speeds.
  • UVLED sources Relative to other UV radiation sources (e.g., mercury lamps), UVLED sources typically generate a smaller amount of heat energy. That said, each UVLED source may produce increased heat as a result of being overdriven. High temperatures may cause problems for the UVLED sources, therefore, dissipating heat generated by each UVLED source is important for a number of reasons. First, excessive heat may slow the rate at which optical-fiber coatings cure. Furthermore, excessive heat can cause the temperature of the UVLED source to rise, which can reduce UV-radiation output. Indeed, continuous high-temperature exposure can dramatically reduce the lifetime of a UVLED source (e.g., by permanently damaging the UVLED source).
  • UV radiation sources e.g., mercury lamps
  • a heat sink 16 may be located behind each UVLED source 14 a (e.g., opposite the portion of the UVLED source 14 a that emits UV radiation).
  • the heat sink 16 may be one-inch square, for example, although other heat sink shapes and sizes are within the scope of the present invention.
  • the heat sink may be formed of a material suitable for conducting heat (e.g., brass, aluminum, or copper).
  • Exemplary heat sinks may include fins or other protrusions that facilitate air cooling of the heat sink.
  • the heat sink may include a heat exchanger that employs a liquid coolant (e.g., chilled water), which circulates within the heat exchanger to draw heat from the UVLED.
  • a piezoelectric heat exchanger may be mounted on the heat sink.
  • each UVLED source typically has an oscillating (e.g., pulsed) output.
  • each UVLED source typically has a repetitively variable output.
  • a UVLED source may be pulsed between high-power (e.g., on) and low-power (e.g., off) states.
  • high-power e.g., on
  • low-power e.g., off
  • each UVLED source may alternatively remain on in its low-power state, albeit having reduced output intensity.
  • the low-power (e.g., off) state provides time for the UVLED source to cool and recover before the next high-power state.
  • pulsed UVLED sources may generate a waveform that approximates a square wave (i.e., a rectangular pulse train having a duty cycle of 50 percent). Because a square wave has a duty cycle of 50 percent, a UVLED source that generates an output approximating a square wave will have high-power and low-power states of equal duration. That said, other duty cycles are within the scope of the present invention.
  • waveforms emitted by exemplary UVLED sources may have a duty cycle of greater than or less than 50 percent (e.g., a rectangular waveform having a duty cycle of 25 percent, 33 percent, or 75 percent).
  • UVLED sources typically generate an approximately rectangular waveform
  • other waveforms are within the scope of the present invention.
  • a UVLED source may generate an approximately triangular, sawtooth, or sinusoidal waveform.
  • Exemplary, square, triangular, sawtooth, and sinusoidal waveforms are depicted in FIGS. 2 a - 2 d , respectively.
  • a coated glass fiber is evenly cured along its length.
  • the degree to which a coated glass fiber is cured is a function of both UV intensity and UV dosage.
  • each UVLED source typically emits UV radiation of varying intensity (e.g., oscillating between high-power and low-power states).
  • the UVLED sources are located at different positions along the curing axis, it will take some time for a point on the coated glass fiber to move from one UVLED source to subsequent UVLED sources. Therefore, to ensure even curing of a coated glass fiber passing through a UVLED array, the high-power and low-power states of the UVLED sources should be timed so that every point on the coated glass fiber passes the same number of UVLED sources that are in a high-power state.
  • the UVLED sources typically are timed to account for (i) the period and duty of the oscillating UVLED outputs and (ii) the time it takes for a point on the coated glass fiber to move from one UVLED source to subsequent UVLED sources.
  • the waveforms (e.g., x n (t)) generated by at least some of the UVLED sources usually are out of phase with one another (i.e., have a phase difference).
  • one UVLED source within the UVLED array may be in a high-power state, while other UVLED sources are in a low-power state.
  • the UVLED sources within an array typically have substantially identical waveforms. That said, it is within the scope of the present invention for the UVLED sources within an array to have varying waveforms.
  • a UVLED array may employ two UVLED sources, the first UVLED source having a duty cycle of 1 ⁇ 3, and the second UVLED source having a duty cycle of 2 ⁇ 3.
  • the number of UVLED sources within a UVLED array may be represented by the variable k.
  • Each UVLED source has an output defining a waveform x n (t) with a period T (e.g., between about one and two seconds).
  • the duty cycle D of the UVLED source within the UVLED array may be represented by the fraction A/B (i.e., the ratio of the time that a UVLED source is in a high-power state versus the total period length).
  • a duty cycle of 1 ⁇ 3 e.g., about 33 percent
  • a UVLED source will be in its high-power state one third (i.e., 1 ⁇ 3) of the time and in its low power state two thirds (i.e., 2 ⁇ 3) of the time.
  • the number of UVLED sources in the UVLED array is typically at least B.
  • a UVLED array may employ five UVLED sources, each having a duty cycle of 20 percent.
  • a UVLED array may employ three UVLED sources, each having a duty cycle of 2 ⁇ 3.
  • each UVLED source may be defined by the cylindrical coordinate system (i.e., r, ⁇ , z).
  • the curing axis i.e., the axis along which a coated glass fiber passes during the curing process
  • a z-axis i.e., the axis along which a coated glass fiber passes during the curing process
  • variable r represents the perpendicular distance of a point to the z-axis (i.e., the distance to the curing axis).
  • the variable r is usually constant. Stated otherwise, the UVLED sources may be positioned approximately equidistant from the curing axis (i.e., the z axis).
  • variable ⁇ describes, within a plane that is perpendicular to the z-axis, the angle between a reference direction and the projection to a point.
  • the variable ⁇ describes the angle between a reference axis (e.g., the x-axis) and the orthogonal projection of a point onto the x-y plane.
  • the z variable describes the position of a reference point along the z-axis.
  • the UVLED sources are separated by a distance d n , which is defined as the distance along the z axis (i.e., ⁇ z) from the first UVLED source in the array to the other UVLED sources in the array.
  • d 2 is the ⁇ z between the first UVLED source and a second UVLED source
  • d 3 is the ⁇ z between the first UVLED source and a third UVLED source.
  • the coated glass fiber has a line speed v f (e.g., between about 10 meters per second and 30 meters per second). Because a glass fiber is typically coated shortly after it is drawn, the line speed of a coated glass fiber is typically the same as the draw speed of the glass fiber.
  • v f e.g., between about 10 meters per second and 30 meters per second.
  • Each UVLED array has a cumulative radiation output (i.e., the sum of the outputs of the UVLED sources).
  • the cumulative radiation output of a UVLED array may be normalized to account for the line speed of a coated glass fiber and the distance between UVLED sources. In other words, the cumulative radiation output of a UVLED array may be normalized to account for the time for a point on the coated glass fiber to travel along the z axis between the UVLED sources within an array.
  • each UVLED array defines (or is otherwise configured to define) a normalized sum x total (t,v f ) that is calculated according to the following equation:
  • each UVLED source within an array is located at the same position along the curing axis (i.e., having the same value with respect to the z axis), then:
  • x total (t,v f ) has a substantially constant value for a given line speed v f (i.e., assuming a constant line speed).
  • v f line speed
  • a UVLED array may have B UVLED sources, each generating a rectangular pulse train having a duty cycle D that is equal to A/B (i.e., representing the ratio of the time that a UVLED source is in a high-power state versus total period length).
  • the rectangular pulse trains generated by the UVLED sources have a maximum value (i.e., maximum output intensity) x n (t) max and a minimum value (i.e., minimum output intensity) x n (t) min .
  • Such an exemplary UVLED array defines a substantially constant x total (t,v f ), and assuming that each UVLED source in the array has substantially the same maximum output intensity x n (t) max , then x total (t,v f ) ⁇ A(x n (t) max +x n (t) min ). In other words, if x total (t,v f ) is substantially constant, then any point on the coated glass fiber will pass A UVLED sources that are in a high-power state.
  • a UVLED array may employ two pulsed UVLED sources.
  • the distance from the first UVLED source to the second UVLED source i.e., d 2
  • the coated glass fiber that is being cured has a line speed v f of 10 meters per second.
  • Each UVLED source generates a square wave output having a duty cycle of 50 percent and a period of one second.
  • the first UVLED source generates a waveform x 1 (t) that is equal to:
  • the second UVLED source generates a waveform x 2 (t) that is equal to:
  • x n (t) max is equal to 1 (i.e., represented here as a unitless 1) and x n (t) min is equal to 0.
  • the normalized sum x total (t,v f ) is equal to x 1 (t)+x 2 (t+d n /v f ), therefore x total (t,v f ) is equal to 1 (i.e., represented here as a unitless 1). Because x total (t,v f ) is equal to a constant value, the coated glass fiber is exposed to UV radiation of consistent intensity and dosage as it passes through the UVLED array.
  • the apparatus for curing glass-fiber coatings may include a plurality of UVLED arrays.
  • FIG. 1 depicts the apparatus 10 having a second UVLED array 11 b (denoted by a dotted circle).
  • FIG. 1 depicts each UVLED array 11 a and 11 b having two UVLED sources 14 a and 14 b
  • the number of UVLED sources in each array may vary.
  • the outputs of the UVLED sources in the first UVLED array may differ from the outputs of the UVLED sources in the second UVLED array.
  • a first UVLED array may employ two UVLED sources, each generating a rectangular pulse train with a duty cycle of 50 percent.
  • a second UVLED array may employ four UVLED sources, each generating a rectangular pulse train with a duty cycle of 25 percent.
  • the UVLED sources in the second array may generate a higher or lower intensity output than the UVLED sources in the first array.
  • Varying the UV intensity of different UVLED arrays may enhance the curing of the glass-fiber coating.
  • it may be desirable to initially expose a coated glass fiber to high intensity UV radiation.
  • it may be desirable to initially expose the optical fiber to lower intensity UV radiation (e.g., between about 10 percent and 50 percent of the maximum exposure intensity) before exposing the optical fiber to high intensity UV radiation (e.g., the maximum intensity to which the optical fiber is exposed).
  • initially exposing the optical fiber to lower intensity UV radiation may be useful in controlling the generation of free radicals in an uncured coating.
  • an apparatus as described herein may include a dark space between one or more UVLED arrays.
  • the apparatus may include a space in which substantially no UV radiation is incident to the coated glass fiber being cured.
  • a pause in the curing process provided by a dark space can help to ensure even and efficient curing of the optical-fiber coatings.
  • a dark space may be useful in preventing too many free radicals from being present in a glass-fiber coating before it is cured (i.e., dark space helps to control free-radical generation).
  • a coated glass fiber may be passed through a dark space. After the coated glass fiber passes through the dark space, it may be exposed to higher-power UV radiation from a second UVLED array to complete the curing process.
  • a curing apparatus employing dark space is disclosed in commonly assigned U.S. Pat. No. 7,322,122 for a Method and Apparatus for Curing a Fiber Having at Least Two Fiber Coating Curing Stages, which is hereby incorporated by reference in its entirety.
  • the apparatus 10 may include a controller 18 that is electrically connected to the UVLED sources 14 a and 14 b .
  • the controller 18 may be capable of adjusting the UV radiation output from the UVLED sources 14 a and 14 b .
  • the controller 18 may change the period, duty cycle, intensity, and/or phase of the outputs of the UVLED sources 14 a and 14 b (e.g., in response to a change in line speed).
  • the line speed of a coated glass fiber may vary during the curing process.
  • the line speed may be affected by changes to the draw speed of the glass fiber; the draw speed of the glass fiber is typically adjusted during the drawing process to ensure a near-constant fiber thickness.
  • a change in line speed can undesirably affect the degree to which a coated glass fiber cures (e.g., by undesirably undercuring or overcuring portions of the coated glass fiber).
  • the output intensity of each UVLED source may be increased at higher line speeds and decreased at lower line speeds, resulting in a change in the maximum output intensity x n (t) max of the UVLED sources.
  • the phase of the UVLED-source outputs may be adjusted to ensure that the normalized x total (t,v f ) for each UVLED array defines a substantially constant value for a given line speed. At different line speeds, x total (t,v f ) may define different substantially constant values.
  • the line speed of a coated glass fiber may be measured using a sensor that is connected to the controller.
  • the sensor then transmits the line speed data to the controller, which can adjust the output of the UVLED sources.
  • the output intensity of the UVLED sources may be controlled by reducing (or increasing) the current flowing to the UVLEDs.
  • the apparatus for curing glass-fiber coatings includes a UVLED array having a plurality of UVLED sources positioned within a cylindrical cavity (or a substantially cylindrical cavity) that has a reflective inner surface.
  • the cylindrical cavity may be made from stainless steel, polished aluminum, or metalized glass, such as silvered quartz, or other suitable material.
  • the interior of the cylindrical cavity defines a curing space.
  • the curing space defines a curing axis along which a drawn glass fiber passes during the curing process.
  • a protective tube surrounds the curing axis.
  • a transparent quartz tube e.g., a quartz tube that is substantially transparent to UV radiation emitted by the UVLED sources
  • the protective tube e.g., a transparent quartz tube
  • the protective tube may have a diameter of about 10 millimeters and a thickness of about 1 millimeter. In general, it is thought that employing a smaller protective tube would improve curing efficiency (i.e., reduce UV radiation waste).
  • the protective tube prevents curing byproducts from damaging and/or fouling the UVLED sources within the cylindrical cavity.
  • volatile components of the optical-fiber coating have a tendency to evaporate during curing.
  • these curing byproducts can precipitate onto both the UVLEDs and the cavity's reflective inner surface.
  • the protective tube can also prevent uncured coating (e.g., delivered by a coating applicator) from being inadvertently deposited within the cylindrical cavity (e.g., spilled onto the UVLED sources and/or the cavity's reflective inner surface).
  • An inert gas e.g., nitrogen
  • gas mixture e.g., nitrogen and oxygen
  • the protective tube may provide an environment having between about 0.1 percent and 5 percent oxygen, such as between about 0.2 percent and 3 percent oxygen (e.g., about 0.31 percent oxygen). Providing a reduced-oxygen environment around the coated glass fiber seems to help reduce the consumption of free radicals by the oxygen.
  • the gas (e.g., nitrogen and/or oxygen) flowing through the protective tube may be heated, such as by employing one or more heat rings positioned around (i) the protective tube and/or (ii) a pipe supplying the gas.
  • the gas flowing through the protective tube may be heated using infrared heaters. Heating the gas flow helps to remove unreacted coating components (e.g., coating monomers) and/or unwanted byproducts present in the cured coating.
  • the cylindrical cavity has a non-circular elliptical cross-section.
  • the cylindrical cavity usually has the shape of an elliptic cylinder.
  • an exemplary elliptic cylinder has a major axis length of 54 millimeters and a minor axis length of 45.8 millimeters.
  • the curing axis corresponds with one of the two line foci defined by the elliptic cylinder.
  • the cylinder's elliptical shape can be modified to compensate for the deleterious effects that may be caused by the protective tube (e.g., refraction and reflection).
  • a UVLED does not emit UV radiation only toward a point or line, but rather emits UV radiation in many directions. Thus, most of the UV radiation emitted by a UVLED source will not directly strike a glass-fiber coating to effect curing. In curing an optical-fiber coating, however, it is desirable that as much UV radiation as possible strike the optical fiber (i.e., a coated glass fiber). As will be understood by those having ordinary skill in the art, curing occurs when UV radiation is absorbed by photoinitiators in the glass-fiber coating.
  • the reflective surface of the cylindrical cavity can reflect otherwise misdirected UV radiation onto an optical fiber for curing, thus reducing wasted energy.
  • any electromagnetic radiation that is emitted from one line focus (regardless of direction) will be directed toward the other line focus after being reflected at the inner surface of the cylinder.
  • each UVLED source may be positioned along the other line focus (i.e., the line focus that does not correspond with a curing axis) such that each UVLED source emits UV radiation in the general direction of the curing axis.
  • FIGS. 2 and 3 depict an exemplary apparatus for curing a coated glass fiber.
  • the apparatus includes a cavity segment 20 .
  • the cavity segment 20 defines a substantially cylindrical cavity 25 having an elliptical shape and a reflective inner surface.
  • the cavity 25 defines a first line focus 21 and a second line focus 22 .
  • One or more UVLED sources 24 are positioned along the first line focus 21 .
  • the cavity segment 20 may include a plurality of UVLED sources 24 positioned contiguously to one another along the first line focus 21 (i.e., directly stacked). In another embodiment, adjacent UVLED sources may be vertically separated by a space of at least about 5 millimeters (e.g., at least about 10 millimeters).
  • the second line focus 22 further defines a curing axis along which a coated glass fiber 26 passes so it can be cured. As depicted in FIG. 4 , UV rays 23 emitted from the UVLED source 24 may reflect off the inner surface of the cavity 25 such that the reflected UV rays 23 are incident to the coated glass fiber 26 .
  • the cavity segment 20 typically includes a single UVLED source positioned within a particular horizontal plane.
  • multiple UVLEDs may be positioned (e.g., at a point other than the first focal line) within a horizontal plane to promote more uniform curing of the glass fiber.
  • an apparatus for curing a coated glass fiber may include a plurality of differently oriented cavity segments. Each cavity may have a common curing axis (e.g., the second focal line), but a different first line focus.
  • a second cavity segment 30 for curing a glass fiber may have a different orientation than the first cavity segment 20 (e.g., the second cavity segment 30 may have UVLED sources positioned along a line focus 31 that differs from the first line focus 21 ).
  • the second cavity segment 30 is rotated 180 degrees relative to the orientation of the first cavity segment 20 . That said, various degrees of rotation may separate adjacent cavity segments. By way of non-limiting illustration, a 45-degree rotation, a 90-degree rotation, or a 135-degree rotation may separate adjacent cavity segments while maintaining the common curing axis.
  • the positioning of a plurality of cavity segments in a three-dimensional arrangement may be defined by the cylindrical coordinate system (i.e., r, ⁇ , z).
  • the curing axis defines a z-axis.
  • the variable r is the perpendicular distance of a point to the z-axis.
  • the variable ⁇ describes the angle in a plane that is perpendicular to the z-axis.
  • the variable ⁇ describes the angle between a reference axis (e.g., the x-axis) and the orthogonal projection of a point onto the x-y plane.
  • the z variable describes the height or position of a reference point along the z-axis.
  • a plurality of cavity segments having the same elliptical dimensions may be positioned in a helical arrangement with the first cavity segment at the position (1, 0, 0), where r is fixed at a constant distance (i.e., represented here as a unitless 1). Additional cavity segments may be positioned, for example, every 90 degrees (i.e., n/2) with a Az of 1 (i.e., a positional step change represented here as a unitless 1).
  • a second cavity segment would have the coordinates (1, ⁇ /2, 1)
  • a third cavity segment would have the coordinates (1, ⁇ , 2)
  • a fourth cavity segment would have the coordinates (1, 3 ⁇ /2, 3), thereby defining a helical configuration.
  • the respective cavity segments are rotated around the curing axis.
  • the respective distances r and z need not be equivalent.
  • the several cavity segments in an arrangement as herein disclosed need not be offset by 90 degrees (e.g., ⁇ /2, ⁇ , 3 ⁇ /2, etc.).
  • the respective cavity segments may be offset by 60 degrees (e.g., ⁇ /3, 2 ⁇ /3, ⁇ , etc.) or by 120 degrees (e.g., 2 ⁇ /3, 4 ⁇ /3, 2 ⁇ , etc.).
  • the cavity segments in an arrangement as discussed herein need not follow a regularized helical rotation.
  • the protective tube interferes with the UV radiation directed toward the curing axis.
  • Applicant simulated directing a 0.1-millimeter wide UVLED having an emission pattern of cos 1.5 ( ⁇ ) directly toward (i.e., employing an emission angle of 0 degrees) a target having a diameter of 250 microns, the approximate diameter of a representative optical fiber.
  • the size of a UVLED refers to its actual size or, if the UVLED is rescaled with a lens, its effective size.
  • the simulation positioned the point source and the target at opposite foci within a reflective elliptic cylinder having a major axis length of 54 millimeters and a minor axis length of 45.8 millimeters. In the absence of a protective tube, nearly 100 percent of the UV rays hit the target.
  • UV rays having an incidence angle other than approximately 90 degrees with the protective tube can be undesirably refracted or reflected.
  • Applicant also simulated directing the UVLED toward a 250-micron target surrounded by a protective tube while employing an emission angle of 90 degrees rather than 0 degrees.
  • Table 1 shows UVLED efficiency (i.e., the percent of UV radiation hitting a 250-micron target) at respective emission angles of 0 degrees and 90 degrees for UVLEDs of various widths.
  • UVLED UVLED Efficiency UVLED Efficiency Width (mm) (0° emission angle) (90° emission angle) 0.1 77 100 0.2 77 79 0.3 77 61 0.4 77 50 0.5 76 43 1 45 25 1.5 31 17 2 24 13 2.5 19 11
  • Table 2 shows UVLED efficiency for a UVLED having a width (or effective width) of 0.1 mm.
  • Applicant further simulated UVLED efficiency for various emission angles using various UVLEDs, where (i) the reflective elliptic cylinder had a major axis length of 54 millimeters and a minor axis length of 45.8 millimeters, (ii) the protective tube had a diameter of 24 millimeters, and (iii) the UVLED had an emission pattern of cos 1.5 ( ⁇ ).
  • FIG. 5 graphically depicts the relationship between UVLED emission angle and UVLED efficiency for UVLEDs of various widths. In brief, FIG. 5 shows that for a UVLED having a width of less than 0.5 millimeter, employing an emission angle of more than 0 degrees improves UVLED efficiency.
  • the UVLED efficiency can be optimally calculated in accordance with the following equation:
  • UVLED efficiency 1001.3x 3 +1166.1x 2 ⁇ 461.6x+140.45, where x is the width of the UVLED, x ⁇ 0.5 millimeter, and the UVLED has an emission pattern of cos 1.5 ( ⁇ ).
  • the optimum emission angle is typically at least about 30 degrees, such as between 30 degrees and 100 degrees (e.g., about 90 degrees for a UVLED having a width of about 0.3 millimeter or less), more typically between about 30 degrees and 60 degrees (e.g., about 45 degrees for a UVLED having a width of about 0.22 millimeter), between each UVLED source and the major axis of the elliptical cylinder.
  • ever smaller UVLEDs may facilitate the deployment of a curing apparatus that can efficiently employ emission angles approaching 180 degrees.
  • such a curing apparatus might employ emission angles greater than about 100 degrees, such as between about 120 degrees and 150 degrees (e.g., about 135 degrees).
  • a protective tube is present within the elliptical cylinder (i.e., surrounding the curing axis)
  • employing an angled UVLED source in this way will provide improved UV absorption during curing.
  • FIG. 6 depicts an exemplary apparatus 50 for curing a coated glass fiber 26 in accordance with the present invention.
  • the apparatus 50 employs one or more angled UVLED sources 24 positioned within a substantially cylindrical cavity 25 having an elliptical shape and having a reflective inner surface.
  • the cavity 25 defines a first line focus 21 and a second line focus 22 .
  • the second line focus 22 defines a curing axis.
  • a coated glass fiber 26 passes along the curing axis during curing.
  • a protective tube 35 surrounds the curing axis and the coated glass fiber 26 .
  • the cavity 25 also defines a major axis 34 that intersects the first line focus 21 and the second line focus 22 .
  • One or more UVLED sources 24 are positioned along the first line focus 21 .
  • Each UVLED source 24 emits UV rays 23 in a distinctive emission pattern.
  • an emission pattern has a line of average emission L avg 23 a (i.e., an average of all the UV rays emitted by the UVLED source 24 ).
  • an UVLED source 24 is angled away from the coated glass fiber 26 .
  • the UVLED source 24 is positioned so that an emission angle ⁇ is defined between the line of average emission L avg 23 a and the elliptical cylinder's major axis 34 .
  • the emission angle ⁇ is typically between about 30 degrees and 100 degrees (e.g., between 30 degrees and 60 degrees), more typically between about 40 degrees and 50 degrees (e.g., 45 degrees).
  • the emission angle ⁇ is typically calculated relative to the line of average emission L avg for a UVLED source (e.g., a single UVLED), it is within the scope of the invention to describe the emission angle ⁇ relative to a line defined by a UVLED source's median or mode (i.e., a line of maximum emission L max ).
  • UV radiation emitted from a UVLED is not emitted from a single point. Therefore, and because of the small size of a coated glass fiber (e.g., a 250-micron diameter), it is desirable to use small UVLED sources (e.g., a 3-millimeter square UVLED or a 1-millimeter square UVLED). In general, a greater percentage of reflected UV radiation will be incident to the coated glass fiber using a small UVLED as compared to using a larger UVLED.
  • small UVLED sources e.g., a 3-millimeter square UVLED or a 1-millimeter square UVLED
  • each UVLED source may include a lens (e.g., a convex lens, such as a biconvex or plano-convex lens) for focusing emitted UV radiation.
  • each lens may have a focus at one of the two line foci (e.g., the line focus not defining a curing axis).
  • a cylindrical lens with a high numerical aperture can be used to rescale a 3-millimeter square UVLED, so that it has an effective width of about 0.4 millimeter or less at the line focus.
  • the apparatus for curing a coated glass fiber may employ one or more optical fibers (e.g., one or more multimode optical fibers) to transmit UV radiation.
  • these optical fibers are typically positioned along the first line focus of the apparatus as an alternative to positioning UVLED sources along the first line focus.
  • each optical fiber is coupled to one or more sources of UV radiation, such as a UVLED source.
  • a plurality of small UVLEDS may be coupled to a plurality of optical fibers in a one-to-one relationship (e.g., 20 UVLEDS and 20 optical fibers).
  • the optical fibers may be arranged in various configurations at or near the first line focus.
  • At least one—and typically each—optical fiber is oriented at the first line focus to provide an emission angle of between about 30 degrees and 120 degrees (e.g., between 45 degrees and 90 degrees).
  • Such optical fibers typically employ a central glass fiber, but may alternatively employ a central plastic fiber.
  • an optical fiber to transmit UV radiation into the cavity may facilitate the deployment of a curing apparatus that can efficiently employ emission angles approaching 180 degrees.
  • a curing apparatus might employ emission angles between 120 degrees and 180 degrees (e.g., about 150 degrees).
  • multimode optical fibers are typically employed for purposes of UV-radiation transmission. That said, it is within the scope of the present invention to employ single-mode optical fibers (e.g., holey glass fibers).
  • An exemplary single-mode optical fiber is a large-mode-area fiber (LMA) that provides a Gaussian beam having a diameter of 0.1 millimeter or less.
  • LMA large-mode-area fiber
  • An exemplary holey optical fiber is disclosed in commonly assigned U.S. patent application Ser. No. 12/692,161 for a Single-Mode Optical Fiber, filed Jan. 22, 2010, (Richard et al.), which is hereby incorporated by reference in its entirety.
  • UVLEDs are capable of emitting wavelengths within a much smaller spectrum than conventional UV lamps. This promotes the use of more of the emitted electromagnetic radiation for curing. That said, the UVLED apparatus (and its related system and method) disclosed herein may be modified to employ mercury lamps and/or fusion lamps as radiation sources (e.g., a supplemental source of UV radiation if insufficient curing is achieved using only UVLEDs).
  • a UVLED source for use in the present invention may be any suitable UVLED that emits electromagnetic radiation having wavelengths of between about 200 nanometers and 600 nanometers.
  • the UVLED may emit electromagnetic radiation having wavelengths of between about 200 nanometers and 450 nanometers (e.g., between about 250 nanometers and 400 nanometers).
  • the UVLED may emit electromagnetic radiation having wavelengths of between about 300 nanometers and 400 nanometers.
  • the UVLED may emit electromagnetic radiation having wavelengths of between about 350 nanometers and 425 nanometers.
  • a UVLED typically emits a narrow band of electromagnetic radiation.
  • the UVLED may substantially emit electromagnetic radiation having wavelengths that vary by no more than about 30 nanometers, typically no more than about 20 nanometers (e.g., a UVLED emitting a narrow band of UV radiation mostly between about 375 nanometers and 395 nanometers). It has been observed that a UVLED emitting a narrow band of UV radiation mostly between about 395 nanometers and 415 nanometers is more efficient than other narrow bands of UV radiation.
  • the UVLED apparatus may employ UVLED sources that have a mean output wavelength at least about 10 nanometers greater than the glass-fiber coating's targeted absorption peak (e.g., at least about 10 to 15 nanometers greater than a targeted absorption peak). That said, it is within the scope of the present invention to employ UVLEDs that have a mean output wavelength within about 10 nanometers (e.g., within about 5 nanometers) of a targeted absorption peak.
  • an exemplary UVLED source emits substantially all of its electromagnetic radiation within a defined range (e.g., between 350 nanometers and 450 nanometers, such as between 370 nanometers and 400 nanometers), the UVLED source may emit small amounts of electromagnetic radiation outside the defined range.
  • 80 percent or more (e.g., at least about 90 percent) of the output (i.e., emitted electromagnetic radiation) of an exemplary UVLED source is typically within a defined range (e.g., between about 375 nanometers and 425 nanometers).
  • UVLEDs can have various emission patterns (e.g., far field pattern).
  • a UVLED employed in accordance with the present invention may have a substantially Lambertian emission pattern.
  • a UVLED source e.g., a UVLED
  • Another exemplary UVLED may have an emission pattern of cos 1.5 ( ⁇ ) or cos 2 ( ⁇ ).
  • UVLEDs are typically much smaller than conventional UV lamps (e.g., mercury bulbs).
  • the UVLED may be a 0.25-inch square UVLED.
  • the UVLED may be affixed to a platform (e.g., a 1-inch square or larger mounting plate).
  • a platform e.g., a 1-inch square or larger mounting plate.
  • other UVLED shapes and sizes are within the scope of the present invention.
  • a 3-millimeter square UVLED may be employed in the apparatus according to the present invention.
  • Each UVLED may have a power output of as much as 32 watts (e.g., a UVLED having a power input of about 160 watts and a power output of about 32 watts). That said, UVLEDs having outputs greater than 32 watts (e.g., 64 watts) may be employed as such technology becomes available. Using UVLEDs with higher power output may be useful for increasing the rate at which optical-fiber coatings cure, thus promoting increased production line speeds.
  • 32 watts e.g., a UVLED having a power input of about 160 watts and a power output of about 32 watts. That said, UVLEDs having outputs greater than 32 watts (e.g., 64 watts) may be employed as such technology becomes available. Using UVLEDs with higher power output may be useful for increasing the rate at which optical-fiber coatings cure, thus promoting increased production line speeds.
  • Each UVLED source may be positioned at a distance of between about 1 millimeter and 100 millimeters (e.g., typically between about 5 millimeters and 30 millimeters) from the optical fiber to be cured (e.g., from the curing axis). More typically, each UVLED source is positioned at a distance of about 25 millimeters from the optical fiber to be cured.
  • UVLEDs may absorb incident electromagnetic radiation, which might diminish the quantity of reflected UV radiation available for absorption by the glass-fiber coating. Moreover, incident UV radiation can damage a UVLED. Therefore, in an apparatus for curing glass-fiber coatings having a plurality of UVLEDs, it may be desirable to position the UVLEDs in a way that reduces UV radiation incident to the UVLEDs. Accordingly, a vertical space of at least about 10 millimeters may separate adjacent UVLEDs. Moreover, the UVLEDs may employ a reflective surface (e.g., a surface coating) that promotes reflection of incident electromagnetic radiation yet permits the transmission of emitted electromagnetic radiation.
  • a reflective surface e.g., a surface coating
  • glass fiber is typically rotated or otherwise subjected to perturbations during drawing operations to reduce unwanted dispersion effects. It is thought that this may further enhance the curing process as herein described.
  • the foregoing description embraces the curing of one or more coating layers on a glass fiber.
  • the disclosed apparatus, system, and method may be similarly employed to cure a buffer layer onto an optical fiber or a ribbon matrix around a plurality of optical fibers.
  • the resulting optical fiber includes one or more coating layers (e.g., a primary coating and a secondary coating). At least one of the coating layers—typically the secondary coating—may be colored and/or possess other markings to help identify individual fibers. Alternatively, a tertiary ink layer may surround the primary and secondary coatings.
  • the resulting optical fiber may have one or more coatings (e.g., the primary coating) that comprise a UV-curable, urethane acrylate composition.
  • the primary coating may include between about 40 and 80 weight percent of polyether-urethane acrylate oligomer as well as photoinitiator, such as LUCIRIN® TPO, which is commercially available from BASF.
  • the primary coating typically includes one or more oligomers and one or more monomer diluents (e.g., isobornyl acrylate), which may be included, for instance, to reduce viscosity and thereby promote processing.
  • compositions for the primary coating include UV-curable urethane acrylate products provided by DSM Desotech (Elgin, Ill.) under various trade names, such as DeSolite® DP 1011, DeSolite® DP 1014, DeSolite® DP 1014XS, and DeSolite® DP 1016.
  • An exemplary coating system is available from Draka Comteq under the trade name C OLOR L OCK® XS .
  • Each coating layer is typically cured before a subsequent coating layer is applied.
  • a coated glass fiber may pass through a first curing apparatus after a primary coating is applied. Once the primary coating has cured, a secondary coating may be applied and cured using a second curing apparatus. Alternatively, both the primary and secondary coatings may be applied, after which the primary and secondary coatings are cured concurrently.
  • an optical fiber with a primary coating typically has an outer diameter of between about 235 microns and about 265 microns ( ⁇ m).
  • the component glass fiber itself i.e., the glass core and surrounding cladding layers
  • the component glass fiber may have an outer diameter of about 125 microns.
  • the primary coating may have an outer diameter of between about 175 microns and about 195 microns (i.e., a primary coating thickness of between about 25 microns and 35 microns)
  • the secondary coating may have an outer diameter of between about 235 microns and about 265 microns (i.e., a secondary coating thickness of between about 20 microns and 45 microns).
  • the optical fiber may include an outermost ink layer, which is typically between two and ten microns thick.
  • the resulting optical fiber may possess a reduced diameter (e.g., an outermost diameter between about 150 microns and 230 microns).
  • the thickness of the primary coating and/or secondary coating is reduced, while the diameter of the component glass fiber is maintained at about 125 microns.
  • the primary coating layer may have an outer diameter of between about 135 microns and about 175 microns (e.g., about 160 microns)
  • the secondary coating layer may have an outer diameter of between about 150 microns and about 230 microns (e.g., more than about 165 microns, such as 190-210 microns or so).
  • the total diameter of the optical fiber is reduced to less than about 230 microns (e.g., about 200 microns).
  • Exemplary coating formulations for use with the apparatus and method described herein are disclosed in the following commonly assigned applications, each of which is incorporated by reference in its entirety: U.S. Patent Application No. 61/112,595 for a Microbend-Resistant Optical Fiber, filed Nov. 7, 2008, (Overton); International Patent Application Publication No. WO 2009/062131 A1 for a Microbend-Resistant Optical Fiber, (Overton); U.S. Patent Application Publication No. US2009/0175583 A1 for a Microbend-Resistant Optical Fiber, (Overton); and U.S. Patent Application Publication No. US2010/0119202 A1 for a Reduced-Diameter Optical Fiber (Overton).
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