OPTICAL FIBRE

Abstract: An optical fibre having good heat resistance, low-temperature resistance, flexural resistance, water absorption resistance and chemical resistance, comprises a core component comprising a polycarbonate or a silica type glass, and a clad component comprising a graft-modified poly (4-methyl-1-pentene) wherein the grafts are formed of unsaturated carboxylic acid or a derivative thereof.

Description: The present invention relates to an optical fibre for transmitting optical signals, particularly to an optical fibre having an excellent heat resistance and flexural resistance. In the prior art for the plastic optical fibres, polystyrene (PS) or polymethyl-methacrylate (PMMA) are used as the core material. However, since such materials have a glass transition temperature (Tg) as low as 100°C, the core material will be softened and become fluid in a high temperature atmosphere of 100°C or higher, and therefore, the upper limit of the usable temperature is about 80°C. To avoid such a disadvantage, various plastic optical fibres using a polycarbonate having excellent transparency and a high Tg of about 150°C have been mentioned (for example, U.S. 3,999,834, Japanese Unexamined Patent Publication (Kokai) No.57-46204 and Japanese Unexamined Patent Publication (Kokai) No.60-32004. According to the method disclosed in U.S. 3,999,834, the polycarbonate is coated with a clad material which then has to be cross linked. As a result the preparation process is rather inconvenient and slow. Japanese Unexamined Patent Publication (Kokai) No.57-46204 discloses a plastic optical fibre having a polycarbonate core coated with a clad material comprising, for instance, poymethylmethacrylate. However, these clad materials are not sufficient for heat resistance compared to polycarbonate. Japanese Unexamined Patent Publication (Kokai) No.60-32004 discloses a plastic optical fibre having a core material comprising a polycarbonate coated with a clad material comprising a polymer of 4-methyl-1-pentene. The polymer may be a copolymer with an unsaturated carboxylic acid such as acrylic acid for improvement of the interlayer peel-off strength between the polycarbonate and the clad material. However due to poor adhesion between the poly (4-methyl-1-pentene) and the polycarbonate the optical fibre has inferior flexural resistance and adequate improvement in adhesion cannot reliably be obtained by mere copolymerisation with an unsaturated carboxylic acid. There is still a need for a polycarbonate optical fibre having improved heat resistance, low temperature resistance and flexural resistance and other properties. Also there is still a need for a quartz optical fibre having improved heat resistance, low temperature resistance and other properties. The present invention provides an optical fibre having improved properties such as improved heat resistance, low-temperature resistance, flexural resistance, water absorption resistance and chemical resistance. The fibre comprises (a) a core component comprising a polycarbonate or a silica type glass, and (b) a clad component comprising at least 85% by weight of a composition of a polymer of 4-methyl-1-pentene characterised in that the composition comprises at least 0.1% by weight of a polymer of (4-methyl-1-pentene) (A) which is partially or entirely graft-modified with an unsaturated carboxylic acid or a derivative thereof at a grafted amount within the range of from 0.01 to 10% by weight of the composition. Preferably, the clad component (b) comprises at least 0.5% by weight of a graft-modified poly (4-methyl-1-pentene). The graft-modified poly-4-methyl-1-pentene (A) may be mixed with a low molecular weight compound (B) having a number-average molecular weight of 300 to 5,000. Polycarbonate that can be used to form the core in the present invention includes various polycarbonates and copolycarbonates obtained by the reactions of dihydroxyl compounds with phosgen or diphenylcarbonate according to known methods. Examples of the dihydroxyl compounds include hydroquinone, rezorcinol, 4,4'-dihydroxy-diphenylmethane, 4,4'-dihydroxy-diphenyl-ethane, 4,4'-dihydroxy-diphenyl-n-butane, 4,4'-dihydroxy-diphenyl-heptane, 4,4'-dihydroxy-diphenyl-phenyl-methane, 4,4'-dihydroxy-diphenyl-2,2-propane (bisphenol A), 4,4'-dihydroxy-3,3'-dimethyl-diphenyl-2,2-propane, 4,4'-dihydroxy-3,3'-diphenyl-diphenyl-2,2-propane, 4,4'-dihydroxy-dichloro-diphenyl-2,2-propane, 4,4'-dihydroxy-diphenyl-1,1-cyclopentane, 4,4'-dihydroxy-diphenyl-1,1-cyclohexane, 4,4'-dihydroxydiphenyl-methylphenyl-methane, 4,4'-dihydroxydiphenyl-ethyl-phenylmethane, 4,4'-dihydroxydiphenyl-2,2,2-trichloro-1,1-ethane, 2,2'-dihydroxydiphenyl, 2,6-dihydroxynaphthalene, 4,4'-dihydroxydiphenyl ether, 4,4'-dihydroxy-3,3'-dichloro-diphenyl ether, and 4,4'-dihydroxy-2,5-diethoxyphenyl ether. Polycarbonates which have a Tg of 140°C or higher are preferred because of their heat resistance. Polycarbonates obtained by use of 4,4'-dihydroxydiphenyl-2,2-propane (bisphenol A) and having a viscosity-average molecular weight within the range from 1.4 to 2.5 x 10⁴ are preferred because they can have optimum transparency, mechanical performance, heat resistance, low-temperature resistance, and impact resistance. Silica type glass that can be used to form the core in the present invention comprises SiO₂ as the main component. It generally also contains components such as Ge, P, C, and/or Al for control of the refractive index. The graft-modified poly (4-methyl-1-pentene) (A) that is used in the clad in the present invention has a grafted amount of an unsaturated carboxylic acid or its derivative within the range of from 0.01 to 10% by weight, preferably from 0.02 or 0.05 to 5% by weight. The amount is often below 1% by weight. The polymer generally has an intrinsic viscosity [η] of 0.3 to 10 dl/g, preferably 0.5 to 5 dl/g, in decaline solvent at 135°C. When a graft polymer with a grafted amount of the unsaturated carboxylic acid or its derivative less than 0.01% by weight is used, there is inadequate improvement in interlayer adhesiveness with the polycarbonate or quartz core. If the grafted amount exceeds 10% by weight the clad will have a lower water absorption resistance and transparency. The graft-modified poly (4-methyl-1-pentene) (A) may be made by grafting on to a poly (4-methyl-1-pentene) (E). This polymer E may be a homopolymer of 4-methyl-1-pentene or a copolymer of 4-methyl-1-pentene with, preferably an α-olefin having 2 to 20 carbon atoms, such as ethylene, propylene, 1-butene, 1-hexene, 1-octene, 1-decene, 1-tetradecene, 1-octadecene, and the like. Polymer E is usually composed mainly of 4-methyl-1-pentene, and preferably contains 85 mol% or more of 4-methyl-1-pentene. It is preferably a crystalline polymer having a melting point (ASTM D 3418) of 230°C or higher and an intrinsic viscosity [η] in decaline solvent at 135°C of 0.5 to 25 (dl/g). The unsaturated carboxylic acid or its derivative to be grafted on to the poly (4-methyl-1-pentene) (E) may be an acid such aa acrylic acid, maleic acid, fumaric acid, tetrahydrophthalic acid, itaconic acid, citraconic acid, chrotonic acid, isocrotonic acid, Nagic Acid (trade mark) (endo-cis-bicyclo [2,2,1] hept-5-one-2,3-dicarboxylic acid) and the like. Derivatives that may be used include acid halides, amides, imides, anhydrides, esters, and the like. Specific examples include maleyl chloride, maleimide, maleic anhydride, citraconic anhydride, monomethylmaleate, dimethylmaleate, glycidylmaleate, and the like. Unsaturated dicarboxylic acids or acid anhydrides thereof are preferred, particularly maleic, Nagic Acid or acid anhydrides thereof. The graft copolymer may be made by various methods known in the art. For example, the process may be carried out by melting the poly (4-methyl-1-pentene) (E) and adding a graft monomer thereto or by adding a graft monomer to a solution of the polymer dissolved in a solvent, and causing polymerisation. It is preferable to perform the reaction in the presence of a radical initiator. The reaction may be carried out generally at a temperature of from 60 to 350°C. The amount of the radical initiator to be used is generally within the range of from 0.001 to 1 part by weight per 100 parts by weight of the poly (4-methyl-1-pentene) (E). Suitable radical initiators include organic peroxides, organic peresters, and otherwise azo compounds. Of these radical initiators, dialkyl peroxides such as dicumyl peroxide, di-tert-butyl peroxide, 2,5-dimethyl-2,5-di(tert-butyl-peroxy)hexyne-3, 2,5-dimethyl-2,5-di(tert-butyl-peroxy)hexane, 1,4-bis-(tert-butyl-peroxy-isopropyl)benzene, and the like are preferred. The graft-modified poly (4-methyl-1-pentene) (A) component of the clad may be entirely graft-modified with an unsaturated carboxylic acid or derivative. Alternatively it may be partially graft modified, i.e., it may be of a mixture of an entirely graft-modified poly (4-methyl-1-pentene) and an unmodified poly (4-methyl-1-pentene) (E), provided that the grafted amount of the unsaturated carboxylic acid or its derivative is within the range 0.01 to 10% as specified above. In this instance, the grafted amount in the graft-modified component of the mixture may be higher, generally up to 25% by weight. The clad used in the present invention may also include a low molecular weight compound (B) having a number-average molecular weight ( M n) of 300 to 5,000, preferably 300 to 2,000 in an amount generally of 1 to 15% by weight, preferably 2 to 10% by weight, based on 100 parts by weight of the composition. As a result adhesiveness with the above core, interface smoothness, flexural resistance, low-temperature resistance, and the like can be further improved. At a level of compound B less than 1% by weight improvement is not exhibited, while at a level exceeding 15% by weight, heat resistance of the composition may be lowered or the low molecular weight compound (B) may seep out on to the interface to make it sticky. A compound having an M n of less than 300 tends to seep out on to the surface and not give an improved flexural resistance and low-temperature resistance. On the other hand, a compound having a M n in excess of 5,000 tends not to give an improved effect of flexural resistance and low-temperature resistance. The component B may be mixed with the previously graft modified poly-4-methyl-1-pentene A or component B may be mixed with the unmodified poly-4-methyl-1-pentene E and the graft polymerisation may then be performed during or after the mixing. Specific examples of the low molecular weight compound B include, for example, mineral oils such as paraffinic process oils, naphthenic process oils, aromatic process oils, and the like, aliphatic hydrocarbon compounds such as paraffinic waxes, low molecular weight polymers obtained by polymerisation (copolymerisation) of -olefins such as ethylene, propylene, 1-butene, and the like, alicyclic hydrocarbon compounds, aromatic hydrocarbons, fatty acids, aliphatic alcohols, fatty acid amides, fatty acid esters, aliphatic mercaptans, aliphatic aldehydes, aliphatic ketones, aromatic ethers, and the like, having 1 or more functional groups such as carboxylic group, hyroxyl group, carbamoyl group, ester group, mercapto group, carbonyl group, and the like, at the terminal ends or internally of aliphatic, alicyclic or aromatic hydrocarbon groups. Of these low molecular weight compounds (B), aliphatic hydrocarbon compounds and alicyclic hydrocarbon compounds are preferable because of their excellent dispersibility in the above graft-modified poly (4-methyl-1-pentene) (A). One preferred class of compounds B are ethylene-α-olefin random copolymers (C) having an ethylene content of 10 to 95 mol%, preferably 40 to 92 mol%, a crystallinity by X-ray of 0 to 20%, a number-average molecular weight ( M n) of 300 to 5000, preferably 300 to 2000, preferably a ratio of weight average molecular weight ( M w) to M n exhibiting the molecular weight distribution M w/ M n of 3 or less, further 2 or less. Another preferred class, that can be used alone or blended with (C) are oligomers (D) represented by the formula: (wherein n and p are integers of 0 or more, m is 0 or 1, and R is having an M n of 300 to 5,000, further 300 to 2,000, preferably M w/ M n of 3 or less, further 2 or less. Compounds C and D are preferred as they have good dispersibility in the graft-modified poly (4-methyl-1-pentene) (A) and give good effects such as interlayer adhesiveness, flexural resistance and low-temperature resistance. In the ethylene-α-olefin random copolymer (C), the α-olefin to be copolymerised with ethylene generally includes α-olefins having 3 to 20 carbon atoms, specifically, for example, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-tetradecene, 1-octadene and the like, which may comprise each individual compound or a mixture of two or more compounds. The copolymer (C), may be made by continuously copolymerising ethylene and an α-olefin in a liquid phase using a catalyst formed from a soluble vanadium compound and an organic aluminium compound in the presence of hydrogen, wherein the vanadium compound concentration in the polymerisation system is 0.3 mmols or more per litre of the liquid phase, and the vanadium compound supplied to the polymerisation medium to 5-fold or less of the vanadium compound concentration in the polymerisation system. A more detailed method is described in Japanese Unexamined Patent Publication (Kokai) No.57-123205. The oligomer (D) is a hydrogenated product of polyisoprene when m is O and R is (in the above formula). It can be easily produced by carrying out anion polymerisation of isoprene in a cyclohexane solution under the co-presence of sec-butyl lithium catalyst and then hydrogenating the polymer in the presence of a nickel naphthenate catalyst. On the other hand, when m is 1, n and p are 2, and R is D is squalane and may be obtained by hydrogenation of squalene with a nickel catalyst. Squalene, which is a starting material of squalane, is contained in liver oil of a deep sea shark, and it can be obtained by subjecting the unsaponified product of shark liver oil to fractional distillation, deacidification and further to fractional distillation in the presence of metallic sodium, or condensing farnesyl chloride or farnesyl bromide in the presence of metallic magnesium, or carrying out Wittig reaction on transgeraniol acetone. In the above description, the ethylene content was measured according to the so-called ¹³C-NMR method, the melting point was measured according to ASTM D 3418, the crystallinity was measured according to the X-ray diffraction method and M n and M w/ M n was measured according to gel permeation chromatography (GPC) by using tetrahydrofuran as the solvent and polystyrene of a known molecular weight and squalane as the standard substances at 25°C. A protective coating may be applied over the outside of the clad. This coating may comprise a thermoplastic resin comprising polypropylene or polyethylene as the main component. Preferably it will have a improved heat resistance as a result of intramolecular cross-linking. To prevent external disturbing light from outside, the coating material may be coloured with a pigment, or a flame retardant may be added therein to improve the flame retardancy. The optical fibre according to the present invention can be prepared according to various methods known in the art. In one the core material and the clad material are extruded simultaneously by the melt composite spinning method using a double nozzle with the core material as the core component and the clad material being covered to a thickness of 5 to 50 µm at the outer circumferential portion. When a polycarbonate is used as the core material, the temperature at the double nozzle portion is controlled generally beteen 220 and 250°C. In another method the core material is first moulded by extrusion and thereafter the clad material is covered by extrusion. In another method the core material is moulded and then a clad material dissolved in a solvent is coated thereon, followed by, for example, drying. The optical fibre according to the present invention comprising a core comprising a polycarbonate or a silica and a clad mainly comprising of the graft-modified poly (4-methyl-1-pentene) has an excellent heat resistance and low-temperature resistance. The polycarbonate core optical fibre of the invention also has an excellent flexural resistance, and therefore, it can be preferably used as a sensor for an optical data link in the engine room of an automobile or for detection of a material for a moulding machine for which heat resistance is demanded. Also, since the quartz glass type optical fibre has an excellent light transmittance, it can be preferably used for optical transmission and optical LAN between private instruments/instruments in a factory. The following are non limiting examples. Example 1 Preparation of maleic anhydride graft-modified poly (4-methyl-1-pentene) After mixing 0.7 part by weight of maleic anhydride and 0.5 part by weight of 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3 with 100 parts by weight of a poly(4-methyl-1-pentene) (hereinafter abbreviated as PMP-1) having an intrinsic viscosity [η]: 3.3 dl/g, Tm = 233°C and containing 6 mol% of 1-hexadecene/1-octadene (weight ratio 1/1) by a Henschel mixer, the mixture was melted and mixed through an extruder set at a temperature of 260°C to obtain a maleic anhydride graft-modified poly (4-methyl-1-pentene) (hereinafter abbreviated as MAH-PMP-1) having an intrinsic viscosity [η]: 1.4 dl/g and a grafted amount of maleic anhydride: 0.5 g/100 g polymer. Preparation of optical fiber After mixing 96% by weight of the above MAH-PMP-1 and 4% by weight of squalane by a Henschel mixer, the mixture was melted and kneaded through an extruder (molding temperature: 250°C) to obtain a composition-I for clad. Subsequently, a polycarbonate (optical grade having a viscosity-average molecular weight of 2.0 to 2.2 x 10⁴) was separately melted through an extruder (molding temperature: 240°C) and then supplied to a double nozzle die, and the composition-I melted through another extruder (molding temperature: 250°C) was supplied to the above-mentioned die to obtain an optical fiber-I with a core diameter of 1,000 µm and a clad thickness of 50 µm. The optical fiber obtained was evaluated according to the methods described below. Light transmission loss: By passing a current of 30 mA through LED with the maximum emission wavelength of 660 nm (FH-511, produced by Stanray), light was emitted from an LED, the optical fibers with lengths of 11 m and 10 m were connected by means of connectors on one side to the LED side and the output energy from the other end was measured by means of an optical power meter, and the difference in outputted light between 11 m and 10 m is represented as the light transmission loss per 1 m (dB/m). Heat resistance test: An optical fiber of 10 m is inserted into a thermostatic bath of 130°C, with the both ends of the optical fiber being taken out into the outer atmosphere from the thermostatic bath, and the change in light transmission loss was measured by use of an LED and optical power meter used as in the measurement of the above light transmission loss to determine the value after the elapse of 1,000 hours. Flexural resistance test: The optical fiber was flexed at ±180° with a radius of curvature of 5 mm, and the changed amount of light transmission loss after repeating this for 1,000 cycles was measured. The results are shown in Table 1. Example 2 Example 1 was repeated except that a composition-II for clad comprising 2% by weight of a maleic anhydride graft-modified poly (4-methyl-1-pentene) obtained in the same manner as in Example 1 having an intrinsic viscosity [η]: 1.0 dl/g, Tm: 233°C, containing 6 mol% of 1-hexadecene/1-octadecene (weight ratio 1/1) and having a grafted amount of maleic anhydride of 1.2 g/100 g polymer, 4% by weight of squalane and 94% by weight of a poly(4-methyl-1-pentene) having an intrinsic vicosity [η]: 2.4 dl/g and containing 6 mol% of 1-hexadecene/1-octadecene (weight ratio 1/1) (hereinafter abbreviated as PMP-2) was used in lieu of the composition-I used in Example 1 to obtain an optical fiber II with a core diameter of 1,000 µm and a clad thickness of 50 µm. The optical fiber II obtained was evaluated according to the methods as described in Example 1. The results are shown in Table 1. Example 3 Example 1 was repeated except that a composition-III (grafted amount of maleic anhydride: 0.5 g/100 g polymer) obtained by mixing 96% by weight of PMP-1 and 4% by weight of squalane and 0.7 parts by weight of maleic anhydride and 0.05 parts by weight of 2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3 (Perhexyne 25B, produced by Nippon Yushi) based on 100 parts of PMP-1 + squalane by a Henschel mixer and thereafter melt mixing the mixture through an extruder set at a temperature of 260°C was used in lieu of the composition-I used in Example 1 to obtain an optical fiber III with a core diameter of 1,000 µm and a clad thickness of 50 µm. The evaluation results are shown in Table 1. Example 4 Example 3 was repeated except for using an ethylene-propylene random copolymer (ethylene content 55 mol%, M w/ M n: 1.4 and the crystallinity: 0%) having a M n of 350 in place of squalane used in Example 3. The results are shown in Table 1. Example 5 Example 1 was repeated except that the MAH-PMP-1 obtained in Example 1 alone (i.e. without added squalane) was used in place of the composition-I used in Example 1. The results are shown in Table 1. Comparative Example 1 Example 1 was repeated except that composition-IV having an intrinsic viscosity [η] of 2.0 dl/g obtained by mixing 96% by weight of PMP-2 and 4% by weight of squalane by a Henschel mixer was used and then melt mixing the mixture through an extruder set at a temperature of 260°C was melt mixed in lieu of the composition-I obtained in Example 1. The results are shown in Table 1. Comparative Example 2 Comparative example 1 was repeated except that the PMP-1 used in Comparative Example 1 was used alone. The results are shown in Table 1. Example 6 Silica preform fused in an electric ove was formed into fibers at a speed of 30 m/min to obtain a quartz core. The composition used in Example 1 was heated and melted at a molding temperature of 250°C in an extruder and the molten composition was coated on the outer periphery of the silica core. Thus, optical fiber VIII having a core diameter of 200 µm and a clad thickness of 100 µm was obtained. The optical fiber VIII obtained above was evaluated in the same manner as in Example 1. As a result, the initial light transmission loss was 48 dB/km at a wavelength of 660 nm, the light transmission loss after the heat resistance test was 50 dB/km, and the light transmission loss after flexural resistance test was 52 dB/km.

Claims: An optical fibre comprising: (a) a core component comprising a polycarbonate or a silica type glass and (b) a clad component comprising at least 85% by weight of a composition of a polymer of 4-methyl-1-pentene characterised in that the composition comprises at least 0.1% by weight of a polymer of 4-methyl-1-pentene which is partially or entirely graft-modified with an unsaturated carboxylic acid or a derivative thereof at a grafted amount within the range of from 0.01 to 10% by weight. An optical fibre according to claim 1 wherein the unsaturated carboxylic acid or its derivative is an unsaturated dicarboxylic acid or an acid anhydride. An optical fibre according to claim 2 wherein the unsaturated carboxylic acid or derivative is maleic acid or maleic anhydride. An optical fibre according to any preceding claim in which the amount of the said graft-modified polymer is at least 0.5% by weight and the grafted amount of carboxylic acid or derivative is 0.02 to 5% by weight. An optical fibre according to any preceding claim in which the amount of the said graft-modified polymer is at least 85% by weight of the clad. An optical fibre according to any preceding claim wherein the clad component contains 1 to 15% by weight of a low molecular weight compound having a number-average molecular weight of 300 to 5,000. An optical fibre according to claim 6 wherein the low molecular weight compound is an aliphatic or alicyclic hydrocarbon compound. An optical fibre according to claim 7 wherein the low molecular weight compound is an ethylene-α-olefin random copolymer which preferably has an ethylene content of 10 to 95 mol%, a crystallinity by X-ray of 0 to 20% and a molecular weight distribution M w/ M n of 3 or less. An optical fibre according to claim 7 wherein the aliphatic hydrocarbon compound is an oligomer (D) represented by formula: (wherein n and p are integers of 0 or more, m is 0 or 1, and R is having a molecular weight distribution M w/ M n of 3 or less. An optical fibre according to claim 9 wherein the oligomer is a hydrogenated product of polyisoprene or is a squalane.

Inventors: ABE, SHUNJI, OHDAIRA, AKIO, TANAKA, AKIRA KAJIGAYA PAKUHAITSU 305, WAKATSUKI, NOBORU
Applicants: FUJITSU LIMITED, MITSUI PETROCHEMICAL INDUSTRIES, LTD.
Application year: 1987
Main classification: G02B6
IPC codes: G02B6, C08F255