1. Field Of The Invention
The present invention relates generally to an optical fiber perform and a method of making an optical fiber preform, and more specifically to an alkali-doped optical fiber perform and a method of making an optical fiber preform doped with an alkali metal oxide.
2. Related Applications
The present invention claims priority to an the benefit of U.S. Provisional Patent Application No. 60/529,024 filed Dec. 12, 2003, the disclosure of which is hereby incorporated by reference herein.
Attenuation is a principal limiting attribute of optical fibers. Optical fiber loss, for example, plays an important role in setting the limiting distance between optical fiber amplifiers. This is particularly important in long distance and ultra-long distance networks such as, for example, undersea applications, where such amplifiers represent a significant system cost, as well as a major factor in system reliability. Consequently there is tremendous commercial interest in reducing attenuation to the lowest possible level.
Silica glass doped with an alkali metal oxide has been shown to be capable of reducing attenuation in optical fibers. Nevertheless, prior art methods of making optical fibers doped with an alkali metal oxide have been impractical for large manufacturing operations.
One broad aspect of the present invention relates to a method of making an optical fiber preform comprising heating an optical fiber precursor in a furnace, exposing the optical fiber precursor to an environment comprising an alkali metal vapor to form an optical fiber precursor doped with an alkali metal oxide, and wherein the alkali metal vapor comprises an alkali metal selected from the group consisting of K, Na, Li, Cs, Rb, and combinations thereof. Preferably, the exposing step is performed for a period of time effective to dope the optical fiber precursor with a concentration of the alkali metal oxide greater than about 0.01 wt. %, more preferably for a period of time effective to dope the optical fiber precursor with a concentration of the alkali metal vapor between about 0.1 wt. % and about 5 wt. %; more preferably 1.0 to 3.0 wt. %; and most preferably 1.0 to 2.0 wt. %. Preferably, the optical fiber precursor is exposed to the alkali metal vapor for at least about 6 hours, more preferably at least about 12 hours, and most preferably between about 12 hours and 72 hours. Preferably, a peak concentration of alkali metal oxide at a first point of the alkali metal oxide doped optical fiber precursor is no more than about 15% greater than a peak concentration of alkali metal oxide at a second point of the alkali metal oxide doped optical fiber precursor. Preferably, the method includes forming additional glass on the alkali metal oxide doped optical fiber precursor. The additional glass is preferably formed by inserting the alkali metal oxide doped optical fiber precursor into a centerline hole of a glass tube; preferably, the glass tube is comprised of glass soot. Optionally, the additional glass may be formed by depositing glass soot onto the alkali metal oxide doped optical fiber precursor. According to one embodiment, the alkali metal oxide doped optical fiber precursor comprises GeO2. The method may include the step of drawing an optical fiber from an optical fiber preform comprising the alkali metal oxide doped optical fiber precursor.
It is to be understood that both the foregoing general description and the following detailed description present embodiments of the invention, and are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention, and together with the description serve to explain the principles and operations of the invention. Where appropriate, identical features have been identically numbered.
According to the present invention, a method of making an optical fiber is proposed which includes doping an optical fiber precursor with an alkali metal oxide. The alkali metal oxide is preferably an oxide of K, Na, Li, Cs, or Rb, or a mixture thereof; more preferably the alkali metal oxide is K2O, Rb2O, Cs2O or mixtures thereof, and most preferably the alkali metal oxide is K2O or Rb2O. Preferably, the peak concentration of alkali metal oxide in the optical fiber precursor is at least about 0.01 wt. %; more preferably at least about 0.1 wt. %; more preferably between about 0.1 wt. % and 5 wt. %; more preferably between 1.0 wt. % and 3.0 wt. %; and most preferably between about 1.0 wt. % and 2.0 wt. %.
The optical fiber precursor may be made by conventional methods, including outside vapor deposition (OVD), vapor axial deposition (VAD) or modified chemical vapor deposition (MCVD). For example, a silica preform may be made using conventional OVD techniques wherein a glass soot producing burner may be used to deposit glass soot onto a target rod to form a soot preform. The amount of glass soot is preferably greater than about 2000 g. Preferably the soot preform has a density between about 0.35 g/cc; more preferably between about 0.35 g/cc and 0.5 g/cc. The glass soot may be pure silica, or the glass soot may be doped to achieve a desired central core refractive index profile. Suitable dopants include Ge, P, F, Al and B.
The target rod is removed from the soot preform leaving a hole extending along a centerline of the soot preform. The soot preform is then dried by conventional methods to remove residual water, and consolidated to form a clear, solid glass. By water we mean the hydroxyl radical OH. OH is responsible for an absorption peak at or about 1383 nm and which absorption peak may extend into the operating wavelength regions of an optical fiber. This peak may have a detrimental effect on the fiber attenuation. Preferably, the soot preform contains less than about 100 ppb by wt. OH after drying; more preferably less than about 20 ppb by wt. Preferably, chlorine drying is used.
More particularly, the soot preform is preferably dried by heating the soot preform to a temperature of at least about 1000° C. in an atmosphere comprising chlorine for at least about 1 hour. Preferably, the soot preform is heated to a temperature of between about 1000° C. and 1200° C. Preferably also, the atmosphere contains at least about 1% chlorine by volume; more preferably at least about 2% by volume. The soot preform is more preferably dried for at least about 2 hours; and may be dried for about 3 hours or more.
To remove, or scavenge, residual chlorine that may remain in the soot preform after the drying step, the soot preform is preferably further heat treated at a temperature of greater than 800° C., more preferably about 1000° C., in a chlorine scavenging atmosphere such as, for example, an atmosphere comprising F. Suitable atmospheres comprising F include, for example, the fluorine-containing gases CF4 or SiF4. Preferably, the fluorine-containing gas is in a concentration of at least about 1% by volume; more preferably at least about 2% by volume. Alternatively, the chlorine scavenging atmosphere may comprise bromine. Preferably, the bromine containing atmosphere comprises bromine in a concentration of at least about 1% by volume; more preferably at least about 2% by volume. For example, liquid bromine may be bubbled to form gaseous bromine and mixed with O2 or an inert gas, such as He or Ar. Preferably, the chlorine content of the soot preform after exposure to the chlorine-scavenging gas is less than about 0.05 wt. %; more preferably less than about 0.02 wt. %; and most preferably less than about 0.01 wt. %.
Once residual chlorine has been scavenged from the soot preform, the soot preform is consolidated into a clear glass article which is preferably substantially chlorine free. The soot preform is consolidated by heating the soot preform to a temperature of at least about 1450° C.; more preferably at least about 1500° C. Drying and consolidation of the soot preform may be accomplished by using a conventional consolidation furnace.
The clear glass article (sometimes referred to as a consolidated preform) is placed in a draw furnace and further drawn (reduced in diameter) according to conventional draw methods. During the draw process, the centerline hole formed in the article by removal of the target rod is preferably closed. This may be accomplished, for example, by reducing the pressure within the centerline hole, wherein ambient atmospheric pressure is sufficient to collapse the hole when the article has reached a suitable draw temperature. The clear glass preform is typically drawn at a temperature greater than about 2000° C. Preferably, the optical fiber precursor produced from the consolidated perform is a glass rod having a diameter of at least about 2 mm; more preferably at least about 3 mm, and most preferably at least about 5 mm; and most preferably between about 3-15 mm. The drawn rod is preferably cut into a plurality of shorter sections. The shorter sections preferably have a length of at least about 1 meter and comprise the optical fiber precursor.
The optical fiber precursor 16 is placed in furnace chamber 18 and heated in furnace chamber 18 at a temperature preferably below the softening point of the optical fiber precursor; more preferably at a temperature between about 1600° C. and 2100° C., even more preferably at a temperature of between about 1700° C. and about 2100° C., and most preferably at a temperature between about 1800° C. and 2100° C. Higher temperatures are preferred as they promote more rapid diffusion of alkali metal oxide within the optical fiber precursor 16.
When the optical fiber precursor has reached an equilibrium temperature in the range described supra, the combined flow of carrier gas and alkali metal vapor (indicated by arrows 36) from vaporization chamber 26 to furnace chamber 18 is begun. Flow of the carrier gas and alkali metal vapor may be controlled, for example, by valve 38 shown in piping 40 connecting vaporization chamber 26 and furnace chamber 18 as illustrated in
Once diffused with sufficient amount of alkali dopant, the optical fiber precursor may be overclad with additional glass. Preferably, the additional glass is sufficient to form an optical fiber preform ready for drawing into an optical fiber, as shown in optional step 46 of method 10 in
Alternatively, the optical fiber precursor may be overclad with additional glass by employing the deposition of soot, sleeving with a glass tube, or both. A preferred sleeving method involves inserting the precursor rod 16 into a central hole of a sleeve 54 as shown in
Silica glass soot is deposited onto a target rod to form a soot preform. The soot preform comprises GeO2. The target rod is removed from the soot preform and the resulting soot tube is dried and consolidated. The soot tube is dried by heating the soot tube in an atmosphere comprising chlorine at a temperature of greater than about 1000° C. The atmosphere contains about 2% chlorine by volume. The soot tube is dried for a period of time greater than about 2 hours. When the soot preform has been dried, it is heated at a temperature of about 1100° C. in an atmosphere comprising fluorine for at least 1 hour to remove residual chlorine. The concentration of residual chlorine in the soot preform after exposure to the fluorine environment is less than about 0.05 wt. %.
At the completion of the heating step, the soot preform is consolidated by heating the soot preform in a conventional consolidation furnace to a temperature of about 1480° C. to form a consolidated glass article. The soot preform is driven through the hot zone of the consolidation furnace at a rate of about 4 mm/min.
The glass article is drawn in a conventional draw furnace into an optical fiber precursor. The optical fiber precursor is a glass rod having an outer diameter smaller than the starting glass article. The optical fiber precursor has a diameter of about 3 mm.
The glass rod is then heated in a furnace to a temperature of about 1900° C. A carrier gas comprising oxygen and an alkali metal vapor is flowed into the furnace, wherein the glass rod is exposed to the alkali metal vapor for about 12 hours. The alkali metal oxide doped glass rod has a peak alkali metal oxide concentration of about 2 wt. %. The alkali metal oxide doped optical fiber precursor may be used as the target rod for the deposition of additional glass soot. The composite glass rod-soot article may then be dried and consolidated to form an optical fiber preform. Alternatively, the alkali metal oxide doped solid glass rod may be inserted into a glass tube after which the glass tube is heated and collapsed onto the glass rod to form an optical fiber preform ready for drawing into an optical fiber. The optical fiber preform is drawn into an optical fiber doped with an alkali metal oxide. The optical fiber has a peak concentration of alkali metal oxide of about 0.2 wt. %.
In another example, a 4 mm diameter pure silica rod is inserted into a furnace chamber of a consolidation furnace having a hot zone temperature of about 1850° C. KBr or KI is heated to about 1000° C. in a reservoir connected to the furnace as shown in
It will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
Number | Date | Country | |
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60529024 | Dec 2003 | US |