Optical fiber with increased mechanical strength

[0001] This application claims the benefit of, and priority to U.S. Provisional Patent Application No. 61/308,583 filed on Feb. 26, 2010 entitled, “Optical Fiber with Increased Mechanical Strength”, the content of which is relied upon and incorporated herein by reference in its entirety.

[0002] The disclosure relates generally to optical fibers and more particularly to optical fibers having improved mechanical strength.

[0003] Mechanical properties of optical fibers are very important, as they influence the way the fibers are woven into cables and also influence the properties of the cables themselves. A particularly important mechanical property is mechanical strength.

[0004] The mechanical strength of a glass material, including the essentially pure or slightly doped silica typically used to make optical fiber, is at least in part a function of components or ingredients used to make the glass. In addition, the mechanical strength of a glass material can be influenced by processing conditions used to make the glass. For example, in planar glass products, the strength of the glass can be significantly increased if the outer surface of the glass is processed to be in a state of compressive stress.

[0005] One embodiment of the disclosure relates to an optical fiber that includes a core, an inner cladding layer surrounding the core, and an over cladding layer surrounding the inner cladding layer. The over cladding layer has a compressive stress of at least 100 MPa.

[0006] An additional embodiment of the disclosure relates to an optical fiber that includes a core and an over cladding layer surrounding the core. The over cladding layer has a compressive stress of at least 100 MPa.

[0007] Another embodiment of the disclosure relates to a method of making an optical fiber. The method includes drawing an optical fiber from an optical fiber preform, wherein the optical fiber includes a core, an inner cladding layer surrounding the core, and an over cladding layer surrounding the inner cladding layer. The over cladding layer has a compressive stress of at least 100 MPa in the finished optical fiber.

[0008] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings.

[0009] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims.

[0010] The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments.

[0014] Optical fibers having increased mechanical strength and methods of their manufacture are disclosed herein. The optical fibers include an over cladding layer that has a compressive stress of at least 100 MPa. By stating that the over cladding layer has a compressive stress of at least 100 MPa, we mean that the over cladding layer is in a state of compression, with the magnitude or absolute value of the compressive stress being at least 100 MPa. Compressive stress values can be determined using the fiber stress measurement technique reported in Wissuchek et al., “Analysis of Residual Stress in Optical Fiber”, Part of the SPIE Conference on Optical Fiber Reliability and Testing, Boston, Mass., September 1999, SPIE Vol. 3848, pp. 34-43, the entire disclosure of which is incorporated herein by reference. The softening point of a glass layer or region is defined as the temperature at which the viscosity of the glass in the temperature or region is equal to about 10^7.6 poise (i.e., 3.981×10⁷ poise). The softening point of the glass and viscosity of the glass at temperatures near the softening point can be determined using ASTM C338-93 (2008) “Standard Test Method for Softening Point of Glass.”

[0015] FIG. 1 schematically illustrates an exemplary embodiment of an optical fiber as disclosed herein. The optical fiber 10 includes a core region 12, an inner cladding layer 14 surrounding the core 12, and an over cladding layer 16 surrounding the inner cladding layer 14, wherein the over cladding layer 16 has a compressive stress of at least 100 MPa, such as at least 150 MPa, and further such as at least 200 MPa. The optical fiber can also be coated with one or more coating layers (not shown), such as coatings comprising a polymeric material.

[0016] FIG. 2 schematically illustrates another exemplary embodiment of an optical fiber as disclosed herein. The optical fiber 10′ includes a core region 12′ and an over cladding layer 16′ surrounding the core 12′, wherein the over cladding layer 16′ has a compressive stress of at least 100 MPa, such as at least 150 MPa, and further such as at least 200 MPa. The optical fiber can also be coated with one or more coating layers (not shown), such as coatings comprising a polymeric material.

[0017] Optical fibers having an over cladding layer with a compressive stress of at least 100 MPa can be produced using methods disclosed herein, wherein the viscosity and radial thickness of the over cladding layer are controlled to be within specified ranges. In addition, the compressive stress in the over cladding layer can also be affected by the tension under which the fiber is drawn. Such fiber can have increased mechanical strength characteristics without a substantial negative impact of the fiber refractive index profile as the result of the stress-optic effect.

[0018] The stress-optic effect is an effect that occurs as a result of stresses in the fiber that alter the index of the fiber from the value that would be expected from composition alone. For example, as a result of stresses induced at draw, the atomic distance as well as the electron shells of atoms in the glass can be influenced. These cause a change in refractive index of the glass, which in cylindrical coordinates is given as:
Δn_r=n_r−n=−B₂σ_r−B₁(σ_θ+σ_z)
Δn_θ=n_r−n=−B₂σ_θ−B₁(σ_r+σ_z)
Δn_z=n_r−n=−B₂σ_z−B₁(σ_θ+σ_r)
where n is the refractive index of unstressed glass, n_r, n_θand n_z are the effective refractive index in the radial, azimuthal and axial direction respectively, and, B₁ and B₂ are the stress-optical coefficients. Correspondingly, the over clad layer material and over clad layer thickness, as well as the draw tension, are chosen such that the change in the index of the core as a result of the stress-optic effect is not large enough to impact the waveguide capabilities of the core.

[0019] By modifying the viscosity of the over cladding layer relative to the layer or region it immediately surrounds, different layers of the fibers support different loads when the fiber is drawn under tension, causing the over cladding layer to have compressive stress during cooling of the fiber as it is being drawn. The viscosity of the over cladding layer can, for example, be modified by doping the over cladding layer with one or more dopants. Such dopants may be added to the over cladding layer during a laydown stage, such as during an outside vapor deposition (OVD) process, or during a consolidation stage. Examples of dopants that can be preferably added during a laydown stage include germania, boron, phosphorous, titania, alumina, phosphorous, and alkali metals, such as sodium and potassium. Examples of dopants that can be preferably added during a consolidation stage include fluorine and chlorine.

[0020] The amount of dopant or dopants in the over cladding layer should preferably be sufficient to modify the viscosity of the over cladding layer within a predetermined range relative to the viscosity of the layer or region it immediately surrounds, wherein the viscosity of the over cladding layer is lower than the viscosity of the layer or region it immediately surrounds over at least a predetermined temperature range. Preferably the temperature range will be a temperature range through which the optical fiber passes while being drawn from an optical fiber preform, such as the softening point of the layer or region being surrounded by the over cladding layer±100° C., and further such as the softening point of the layer or region being surrounded by the over cladding layer±200° C., and even further such as the softening point of the layer or region being surrounded by the over cladding layer ±400° C. Examples of preferred temperature ranges include from about 1200° C. to about 2000° C., such as from about 1400° C. to about 1800° C. Preferably, the ratio of the viscosity of the over cladding layer to the viscosity of the layer or region it immediately surrounds at any temperature of the optical fiber in the predetermined temperature range is from about 0.1 to about 0.9, more preferably from about 0.1 to about 0.5, such as from about 0.1 to about 0.2 and further such as from about 0.2 to about 0.5.

[0021] For example, in the embodiment illustrated in FIG. 1, the ratio of the viscosity of the over cladding layer to the viscosity of the inner cladding layer at any temperature of the optical fiber in the range of the softening point of the inner cladding layer±200° C. is preferably from about 0.1 to about 0.9, more preferably from about 0.1 to about 0.5, such as from about 0.1 to about 0.2 and further such as from about 0.2 to about 0.5. In a particularly preferred embodiment, the ratio of the viscosity of the over cladding layer to the viscosity of the inner cladding layer at any temperature of the optical fiber in the range of from about 1400° C. to about 1800° C. is from about 0.1 to about 0.9, more preferably from about 0.1 to about 0.5, such as from about 0.1 to about 0.2 and further such as from about 0.2 to about 0.5.

[0022] For example, in the embodiment illustrated in FIG. 1, the difference in the softening point of the over cladding layer and the softening point of the inner cladding layer is preferably greater than 40° C., such as greater than 60° C., further such as greater than 80° C., still further such as greater than 100° C., and yet still further such as greater than 120° C. For example, in preferred embodiments, the difference in the softening point of the over cladding layer and the softening point of the inner cladding layer is between 40° C. and 150° C., such as between 60° C. and 150° C., and further such as between 80° C. and 150° C., and still further such as between 100° C. and 150° C., wherein the softening point of the over cladding layer is lower than the softening point of the inner cladding layer.

[0023] In the embodiment illustrated in FIG. 2, the ratio of the viscosity of the over cladding layer to the viscosity of the core at any temperature of the optical fiber in the range of the softening point of the core±200° C. is preferably from about 0.1 to about 0.9, more preferably from about 0.1 to about 0.5, such as from about 0.1 to about 0.2 and further such as from about 0.2 to about 0.5. In a particularly preferred embodiment, the ratio of the viscosity of the over cladding layer to the viscosity of the core at any temperature of the optical fiber in the range of from about 1400° C. to about 1800° C. is from about 0.1 to about 0.9, more preferably from about 0.1 to about 0.5, such as from about 0.1 to about 0.2 and further such as from about 0.2 to about 0.5.

[0024] In the embodiment illustrated in FIG. 2, the difference in the softening point of the over cladding layer and the softening point of the core is preferably greater than 40° C., such as greater than 60° C., further such as greater than 80° C., still further such as greater than 100° C., and yet still further such as greater than 120° C. For example, in preferred embodiments, the difference in the softening point of the over cladding layer and the softening point of the core is between 40° C. and 150° C., such as between 60° C. and 150° C., and further such as between 80° C. and 150° C., and still further such as between 100° C. and 150° C., wherein the softening point of the over cladding layer is lower than the softening point of the core.

[0025] In preferred embodiments, dopants can be added in amounts and ratios that not only modify the viscosity of the over cladding layer relative to the viscosity of the layer or region it immediately surrounds but also modify the refractive index of the over cladding layer relative to the layer or region it immediately surrounds. In one set of preferred embodiments, one or more dopants can be added to lower the refractive index of the over cladding layer relative to the layer or region it immediately surrounds. Examples of such dopants include boron and fluorine. In another set of preferred embodiments, one or more dopants can be added to raise the refractive index of the over cladding layer relative to the layer or region it immediately surrounds. An example of such a dopant is germania. In yet another set of preferred embodiments, one or more dopants can be added such that the refractive index of the over cladding layer is approximately the same as the refractive index of the layer or region it immediately surrounds. For example, if the layer or region immediately surrounded by the over cladding layer is pure or substantially pure silica, the over cladding layer can be codoped with germania (an index raising dopant) and fluorine (an index lowering dopant) in a ratio that allows for the over cladding layer to have approximately the same refractive index as pure or substantially pure silica.

[0026] In addition to the viscosity of the over cladding, the radial thickness of the over cladding can be controlled to be within a predetermined range. To examine the effects of viscosity and radial thickness a series of exemplary single mode fibers were modeled having varying over cladding radial thickness and over cladding/inner cladding viscosity ratios. Each of the modeled fibers had a 125 μm diameter with a core having a 4.4 μm radius, wherein the core was modeled to be doped with about 7 wt % germania (corresponding to a maximum refractive index relative to pure silica of about 0.35%) and surrounded by an inner cladding layer of substantially pure silica, which in turn was surrounded by a over cladding layer, wherein for different exemplary fibers, the viscosity and radial thickness of the over cladding layer were allowed to vary. For each of the examples reported in Table 1, the viscosity ratio of the over clad layer to the inner clad layer was determined at a temperature of about 1650° C., which is about the softening point of the inner cladding layer, at which temperature the viscosity of the inner clad layer in each of the examples is about 3.981×10⁷ poise. The exemplary fibers are set forth in Table 1.

[0027]

TABLE 1
		Viscos-	Radial	Core	Inner clad	Over clad
		ity ratio	thick-	effective	layer	layer
		of over	ness	index	effective	effective
		clad lay-	of over	relative	index	index
Exam-	Draw	er to in-	clad	to pure	relative to	relative to
ple	tension	ner clad	layer	silica	pure silica	pure silica
No.	(g)	layer	(μm)	(% Δ)	(% Δ)	(% Δ)
1	200	0.9	27.5	0.3542	−0.0039	0.0019
2	200	0.9	37.5	0.3535	−0.0050	0.0009
3	200	0.9	47.5	0.3531	−0.0056	0.0003
4	200	0.5	27.5	0.3393	−0.0425	0.0133
5	200	0.5	37.5	0.3323	−0.0388	0.0075
6	200	0.5	47.5	0.3266	−0.0479	0.0029
7	200	0.2	27.5	0.3175	−0.0624	0.0306
8	200	0.2	37.5	0.2880	−0.1094	0.0211
9	200	0.2	47.5	0.2535	−0.1646	0.0101
10	200	0.1	27.5	0.3052	−0.0820	0.0402
11	200	0.1	37.5	0.2533	−0.1649	0.0319
12	200	0.1	47.5	0.1688	−0.2997	0.0184

[0028] The lower viscosity in the over clad layer relative to the viscosity in the inner clad layer, as shown in Table 1, can, for example, be achieved by adding dopants in the over clad layer in the amounts set forth below in Table 1A.

[0029]

TABLE 1A
Viscosity ratio of over clad		Wt %
layer to inner clad layer	Dopant	Dopant
0.9	fluorine	0.09
0.5	fluorine	0.61
0.2	fluorine	1.43
0.1	fluorine	2.04
0.9	germania	1.58
0.5	germania	10.38
0.2	germania	24.10
0.1	germania	34.48
0.9	titania	0.73
0.5	titania	4.78
0.2	titania	11.09
0.1	titania	15.87

[0030] In addition, the over cladding layer can be codoped with germania and fluorine in a ratio that allows for the over cladding layer to have approximately the same refractive index as pure or substantially pure silica as set forth, for example in Table 1B.

[0031]

TABLE 1B
Viscosity ratio of over clad	Wt %	Wt %
layer to inner clad layer	germania	fluorine
0.9	0.42	0.07
0.5	2.79	0.45
0.2	6.47	1.04
0.1	9.26	1.49

[0032] In preferred embodiments of the embodiment illustrated in FIG. 1, when fluorine is used as a dopant in the over clad layer, it can be present in the over clad layer, alone or in combination with one or more other dopants, in amounts ranging from 0.05 to 2.5 wt %, such as from 0.1 to 1.5 wt %, and further such as from 0.2 to 1.0 wt %. When germania is used as a dopant in the over clad layer, it can be present in the over clad layer, alone or in combination with one or more other dopants, in amounts ranging from 0.25 to 35 wt %, such as from 0.5 to 25 wt %, and further such as from 1 to 10 wt %. When titania is used as a dopant in the over clad layer, it can be present in the over clad layer, alone or in combination with one or more other dopants, in amounts ranging from 0.25 to 20 wt %, such as from 0.5 to 10 wt %, and further such as from 1 to 5 wt %. When germania and fluorine are combined as codopants in the over clad layer, they can, for example, be present in amounts ranging from 0.3 to 10 wt % germania in combination with from 0.05 to 1.5 wt % fluorine, such as from 0.6 to 6 wt % germania in combination with from 0.1 to 1 wt % fluorine, and further such as from 1 to 3 wt % germania in combination with from 0.15 to 0.5 wt % fluorine.

[0033] As can be seen from Table 1, the effective index of the core appears to be affected by the radial thickness of the over clad layer, particularly at lower viscosity ratios of over clad layer to inner clad layer. Such effects are believed to be the result of the stress-optic effect described above.

[0034] Accordingly, the radial thickness of the over cladding layer is preferably large enough to have a sufficiently high compressive stress without the stress in the core region being so large as to substantially affect the effective index of the core of the fiber. Preferably, the radial thickness of the over cladding layer is from about 3% to about 30% of the radial thickness of the optical fiber, and even more preferably from about 5% to about 20% of the radial thickness of the optical fiber. For example, when the optical fiber has a diameter of 125 μm, the over cladding layer may have, for example, a radial thickness of between about 2.5 and about 17.5 μm, such as between about 7.5 and 12.5 μm. When the optical fiber has a diameter of 250 μm, the over cladding layer may have, for example, a radial thickness of between about 5 and about 35 μm, such as between about 15 and 25 μm.

[0035] The amount of the over clad layer compressive stress is also influenced by the tension under which the optical fiber is drawn. Preferably, the optical fiber is drawn at a draw tension of between about 100 g and 400 g, such as a draw tension of between about 200 g and 300 g.

[0036] Table 2 lists further examples of modeled single mode optical fiber having a 125 μm diameter with a core having a 4.4 μm radius, with a core doped with about 7 wt % germania. The core was surrounded by an inner cladding layer of substantially pure silica, which in turn was surrounded by a over cladding layer, wherein for different exemplary fibers, the viscosity and radial thickness of the over cladding layer were allowed to vary as was the tension under which the fiber was drawn. For each of the examples reported in Table 2, the viscosity ratio of the over clad layer to the inner cladding layer was determined at a temperature of about 1650° C., which is about the softening point of the inner clad layer, at which temperature the viscosity of the inner clad layer in each of the examples is about 3.981×10⁷ poise. The difference between the softening point of the inner clad layer and over clad layer as reported in Table 2 can alternatively be understood as the amount (in ° C.) that the softening point of the over clad layer is less than about 1650° C.

[0037]

TABLE 2
			Difference
			between		Core	Inner clad	Over clad
		Viscosity	softening		effective	layer	layer
		ratio of	point of	Radial	index	effective	effective	Compres-
		over clad	inner clad	thickness	relative	index	index	sive stress
	Draw	layer to	and	of over	to pure	relative to	relative to	in over
Example	tension	inner clad	over clad	clad layer	silica	pure silica	pure silica	clad layer
No.	(g)	layer	(° C.)	(μm)	(% Δ)	(% Δ)	(% Δ)	(MPa)
13	200	0.2	95	17.5	0.3359	−0.0331	0.0360	108
14	200	0.2	95	12.5	0.3433	−0.0211	0.0380	115
15	200	0.2	95	7.5	0.3490	−0.0113	0.0407	120
16	200	0.2	95	2.5	0.3546	−0.0032	0.0420	126
17	200	0.1	133	17.5	0.3314	−0.0403	0.0444	130
18	200	0.1	133	12.5	0.3409	−0.0250	0.0450	130
19	200	0.1	133	7.5	0.3484	−0.0130	0.0470	140
20	200	0.1	133	2.5	0.3543	−0.0035	0.0480	140
21	300	0.5	42	7.5	0.3597	−0.0099	0.0350	105
22	300	0.5	42	2.5	0.3640	−0.0030	0.0388	115
23	300	0.2	95	17.5	0.3348	−0.0496	0.0545	160
24	300	0.2	95	12.5	0.3459	−0.0318	0.0581	173
25	300	0.2	95	7.5	0.3552	−0.0170	0.0610	181
26	300	0.2	95	2.5	0.3629	−0.0048	0.0635	180
27	300	0.1	133	17.5	0.3280	−0.0604	0.0665	190
28	300	0.1	133	12.5	0.3423	−0.0370	0.0687	204
29	300	0.1	133	7.5	0.3535	0.0197	0.0705	210
30	300	0.1	133	2.5	0.3625	−0.0054	0.0720	214

[0038] Table 3 lists examples of multimode optical fiber that were processed having 250 μm diameter with a core having a diameter of about 190 μm. The core, which was comprised of substantially pure silica, was surrounded by an over cladding layer, which was co-doped with boron and fluorine.

[0039]

TABLE 3
	Fiber			Draw		Boron	Fluorine
Ex-	outer	Core	Draw	temper-	Draw	in over	in over
ample	diameter	diameter	speed	ature	tension	cladding	cladding
No.	(μm)	(μm)	(m/s)	(° C.)	(g)	(wt %)	(wt %)
31	250	190	3.5	1875	>300	3.28	1.36
32	250	190	2.75	1900	<200	3.28	1.36
33	250	190	2.75	1915	<200	3.28	1.36
34	250	190	2.75	1930	<200	3.28	1.36
35	250	190	2	1930	<100	3.28	1.36

[0040] Stress as a function of radial position for the optical fibers of Table 3 is illustrated in FIG. 3 (wherein a negative value is indicative of a compressive stress or, in other words, the magnitude of the compressive stress is the absolute value of the negative values shown in FIG. 3). As can be seen from FIG. 3, the over cladding layer, which has a radial thickness of about 30 μm, has a compressive stress of greater than 150 MPa when, as in Example 31, the draw tension is greater than 300 g. In contrast, as shown in FIG. 3 for Examples 32-35 (which are comparative in nature), when the draw tension is lower, the compressive stress is less than 100 MPa.

[0041] In preferred embodiments, the over cladding layer of optical fibers corresponding to the embodiments set forth in Table 3 can be doped with between about 12 wt % and 1 wt % boron and 2.5 wt % and 1 wt % fluorine, such as between about 5 wt % and 1 wt % boron and 2 wt % and 1 wt % fluorine, and further such as between about 3 wt % and 1 wt % boron and 1.5 wt % and 1 wt % fluorine.

[0042] By having an over cladding layer that has a compressive stress of at least 100 MPa, optical fibers disclosed herein can have improved mechanical properties, particularly improved mechanical strength. For example, such optical fiber can be expected to have high tensile strength. By comparison, conventional optical fiber that does not have such an over cladding layer will have an outside compressive stress that is much lower, such as less than 25 MPa, and will have a substantially lower tensile strength.

[0043] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred.

[0044] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the invention. Since modifications combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and their equivalents.