Method and apparatus for manufacturing an hermetically coated optical fiber

Abstract: A mass production method of and apparatus for hermetically coating optical fiber (1) where a bare fiber (1) drawn from a preform is hermetically coated by CVD method in a reactor vessel (2), wherein a liquid (13) flushes solid particles or by-products sticking to the reactor inner wall. The liquid (13) may be supplied continuously or intermittently, to flush carbon particles generated during carbon coating process. The invention enables to produce a long hermetic coating optical fiber (1) without choking the reactor, and improves a yield rate and productivity.

Description: Background of the Invention (Field of the invention) The present invention relates to a method and an apparatus for manufacturing a hermetically coated optical fiber, and more particularly to such a method and an apparatus suitable for mass production. (Related Background art) A hermetically coated optical fiber is an effective product for preventing ambient gases such as water, hydrogen etc. from adhering to the optical fiber or permeating through the optical fiber. Generally, inorganic materials such as metals including alloys and carbon etc. are used as coating materials. Above all, carbon coating is one of the most excellent ones in term of its chemical stability and fine grained structure etc. and one of the coating processes is a chemical vapor deposition (CVD) process in which reactant gas reacts chemically to deposit coating material on the optical fiber surface, this process being advantageous in terms of coating speed and quality of the layer. Conventional apparatuses for performing the above mentioned technologies, are described, for example, in United States Patent No. 4,790,625 or European Patent Application No. 0,308,143. In such apparatuses or methods, the reactor vessels typically have a seal gas inlet port and a reactant gas inlet port at their upper end; and a waste gas discharge port at their lower end. A formed fiber of high temperature is hermetically coated thermo-chemically in the reactor vessel between the reactant gas inlet port and the waste gas discharge port. Usually in those processes, an optical fiber is drawn from a preform in a draw furnace, before it is provided with a hermetic coating. A sufficient temperature (about 1300 °C) is necessary for the formation of the coating particles and to ensure that these particles are maintained at the fiber surface without the need for additional heating means. In said conventional apparatuses, solid particles such as carbon generated in a vapor phase tend to be deposited on the inner wall of the reactor vessel. When it was attempted to coat a long length of the fiber, the solid particles were gradually deposited also on the inner wall of the reactor vessel so that the vessel became clogged during the long period of time required for the process. Consequently, fiber forming for long lengths becomes impossible. Without solving the problem, a yield rate of the optical fiber could not be improved and high productivity could not be attained. Summary of the Invention It is an object of the present invention, to eliminate the above mentioned drawbacks of the prior art. It is further object of the present invention to develop an effective method for manufacturing a hermetic coating optical fiber in a long length. It is a further object of the present invention to provide an apparatus for manufacturing a hermetically coated optical fiber in a long length, avoiding deposition of solid particles on an inner wall of a reactor vessel. To realize the above-described objects, the present invention provides a method of manufacturing a hermetically coated optical fiber as defined in the accompanying Claims 1 to 5; and an apparatus for manufacturing a hermetically coated optical fiber as defined in the accompanying Claims 6 to 10. The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not to be considered as limiting the present invention. Brief Description of the Drawings FIG. 1 shows a basic structure of an embodiment of the present invention; FIG. 2 is an outline showing another embodiment of the present invention. FIG. 3 is a perspective view showing a partial cutaway of the embodiment of Fig.1. FIG. 4 is a perspective view showing a partial cutaway of the other embodiment of the present invention. Description of the Preferred Embodiment As shown in FIG. 1, a reactor vessel 2 is provided with an upper seal gas inlet port 3, a reactant gas inlet port 4 (reactant gas is supplied to the reactor vessel from 4 directions), a waste gas discharge port 6 and a lower seal gas inlet port 5 respectively in this order from the upper to the lower extent of the reactor vessel 2. The reactor vessel 2 is furnished with a liquid inlet port 7 for introducing a liquid 13 which prevents solid particles from sticking to an inner wall of the reactor vessel and/or removes solid particle layer deposited on the inner wall of the vessel, and a reservoir 8 for keeping the liquid 13, at the upper part of the reactor vessel. The reactor vessel 2 is also furnished with a waste liquid discharge port 9 and a waste liquid treating apparatus 12 at the lower part thereof. Those elements are made of quartz glass or the like. The liquid 13 is supplied to the reservoir 8 through the liquid inlet port 7 continuously or intermittently at an optional interval. The accumulated liquid overflows a weir 81 to the inner wall of the reactor vessel 2, uniformly along the circumference of the inner wall, and the liquid 13 flows down on the inner wall. In this process, the liquid 13 takes in particles formed in a vapor phase process which are going to stick to the inner wall of the reactor vessel, and quickly discharges the particles out of the reactor vessel. Where the liquid 13 is supplied intermittently, the particles are supposed to be flushed away after the particles once deposited to form a solid particle layer. The weir 81 is formed as horizontally as possible so that the liquid 13 overflows the weir supplied uniformly along all over the circumference of the inner wall of the reactor. In addition, the top ridge of the weir may be indented as saw teeth, to distribute the liquid uniformly. A plurality of small holes may be provided circumferentially at the bottom of the weir 81, through which the liquid 13 can flow out to be supplied to the inner wall. In this embodiment, the liquid introduced through the liquid inlet port 7 must flow out through the small holes first and there after the surplus overflows the weir 81. Even when the supply of the liquid through the inlet port 7 is stopped, the liquid retained in the reservoir 8 is continued to flow out to the inner wall of the reactor vessel 2 through the small holes for a while. The waste liquid is discharged through the waste liquid discharge port 9 to the waste liquid treating apparatus wherein the waste liquid is treated. The liquid reclaimed in the waste liquid treating apparatus 12 may be recycled, or it is possible to construct a circulating system. An exhaust or waste gas is evacuated after it is discharged through the waste gas discharge port 6 to the waste gas treating apparatus 11 and is treated there. A protective pipe 10 should preferably be furnished for the fiber not to come in contact with the waste. Reference numeral 20 denotes the hermetically coated fiber. Generally, liquid flowing down a vertical wall is apt to gradually gather into a few stripes of stream, as it goes down. It is because the flow speed becomes higher and the thickness of liquid flow becomes too thin to keep a flat layer of flow, and surface tension also acts to make the liquid surface as small as possible. Solid particles generated in a gas phase are easy to deposit on the inner wall where the reactant gas stagnates on the reactor vessel. The bottom part of the reactor vessel is a place where the gas tends to stagnate, and the liquid stream layer tends to be thin, and solid particles are apt to be deposited in quantity. In order to prevent this, a second liquid inlet port 85 and a second reservoir 86 may be furnished at the bottom part of the reactor vessel as shown in FIG. 4. In place of the second reservoir 86, liquid inlet holes may be furnished in the wall of the reactor vessel. In order to prevent liquid splashes from coming in contact with the fiber to damage it, and also keep a constant flow of liquid, an apparatus as shown in FIG. 2 is effective. An inner pipe of a reactor vessel is denoted by reference numeral 21 and an external pipe is by 22. The inner pipe is provided with a plurality of openings, which are preferably small to prevent liquid from splashing to the fiber. This embodiment is especially effective when the liquid flows intermittently and the flow rate is high, consequently many splashes are easy to be generated. Usually a small amount of liquid is supplied continuously to the inner pipe, although the gas will not stagnate in the inner pipe and only a small amount of solid particles would deposit on it even without the liquid supply. The reservoir 8 is provided with holes of about 0.5 to 3 mm in diameter and a few to more than ten in number at the bottom, along the inner wall of the reactor vessel. The liquid supplied through the holes flows uniformly on the inner wall of the reactor vessel. The liquid may overflow the weir 81. A protective pipe 10 is provided for preventing the liquid from coming in contact with the optical fiber and also forming a reservoir. In the present invention, a liquid with relatively low viscosity may be used when the liquid is supplied intermittently. In this event, solid particle layer which deposited once on the inner wall is flushed away and sometimes a rigidly sticked layer could not be removed. The sticked layer is at most a few mm thick and is not very big trouble. When the liquid is supplied continuously, a liquid with relatively high viscosity may preferably be used to prevent the liquid from splashing regularly. In this event, the inner wall of the reactor vessel is always covered with the liquid and solid particles could not stick to the inner wall, and are effectively evacuated. However, a liquid with low viscosity can also be used even when supplied continuously, although the supply amount may be somewhat increased. Water is one of the suitable liquids for the present invention. Water is most easily handled and very cheap, and can be treated easily after flowing to waste. And when an interface activator such as a kitchen or industrial detergent on the market (for example, SHOKO Co.'s Kurihn Ehsu S (Trade Mark)(Clean Ace S), SHARP SYSTEM PRODUCTS Co.'s Ekitai Senjohzai M-251L (Trade Mark)(Liquid Detergent M-251L), YUHO CHEMICAL Co.'s Kurihn Ruhm You Senjohzai CC-85(Trade Mark)(DETERGENT FOR CLEAN ROOM CC-85), IUCHI Co.'s Pyua Sofuto PS(Trade Mark)(PURE SOFT PS), IUCHI Co.'s Senzai Burukurihn 90, Burukurihn 70, Resukon Ls (Trade Mark)(DETERGENT Blue Clean 90, Blue Clean 70, Ls Con Ls)) is added to water, the water becomes outstandingly easy to wet the solid particles and/or the inner wall of the reactor vessel. Consequently, the solid particles are easily and quickly captured without needing to be flicked away by the water surface. Additionally, the inner wall surface of the reactor vessel becomes also easy to be wetted and any build up of a solid particle layer is very effectively eliminated. Among low viscosity liquids, there are fluorine family inert liquids, and the like on the market (for example, Sumitomo 3M Co.'s Furorinahto (FLUORINERT)(Registered Trade Mark)). And silicone oil family (for example, Toshiba's SILICONE OILS of TSF 458, 451 series, 405 and 431, and YF33 (Trade Mark))can be adopted depending on the purpose, since one with preferred viscosity can be easily obtained in a wide range (for example a viscosity of 10 CST to 500000 CST is available for TSF 451 series). Anyhow, the liquid should be preferably as inert as possible to the reactant gas, but also it should be of no trouble for the characteristics of the product. As mentioned above, the inner wall had better be as hydrophilic as possible to be wetted by the liquid. Then the inner wall of the reactor vessel may be treated to be hydrophilic. The inner wall can be hydrophilic or easy to be wetted by being of frosted glass, lined with glass fibers or glass fiber cloth and the like or scored with vertical stripes. The glass fiber cloth may preferably be woven using fibers of hundred to several hundreds micron-meter in diameter. As described above, the liquid should be basically as inert as possible to the reactant gas, but on the contrary alkaline liquid sometimes improves the process in case that a by-product from reaction is acid. It is because the by-product reacts to the liquid, that is, the liquid plays a role of waste gas treatment. In a typical case that reactant gases are C 2 H 4 + 2CHCl 3 , C 2 H 4 + 2CHCl 3 → 4C(s) + 6HCl ↑ the generated hydrogen chloride (HCl) gas is absorbed by the liquid, resulting in accelerating the reaction. Consequently, a yield rate per unit of reactant gas is improved and consumption of the reactant gas can be reduced. Examples of alkaline liquid are aforementioned Liquid Detergent M-251L, DETERGENT FOR CLEAN ROOM CC-85, PURE SOFT PS, DETERGENT Blue Clean 90, Blue Clean 70, and Ls Con Ls. Further by flowing a liquid temperature-controlled by a thermo-controller 90, or thermally controlling the reactor vessel to cool the reactor vessel to decrease the temperature of a gas, the generation of the particle can be suppressed. By cooling the reactor vessel with liquid, the temperature gradient is caused between a high temperature optical fiber and a low temperature reactor vessel and as the result the particles generated in the reactor vessel have tendency to approach the inner wall of the reactor vessel by Thermophoresis effect caused by the temperature gradient. Therefore, the attack to the optical fiber can be prevented. Using the removal by the liquid according to the present invention as described above, a coating process in a long period of time is possible since no solid particles deposit on the inner wall of the reactor vessel or if any it can be minimized. Examples are presented as follows. Example 1 This example 1 was obtained by a method according to the prior art. With reactant gases of C 2 H 4 and CHCl 3 , and a CHCl 3 carrier gas of He, a quartz fiber was coated with carbon. Nitrogen gas N 2 was used as a upper seal gas, and air as a lower seal gas. Respective amounts of gases were set at as the following. C 2 H 4 100 cc/min CHCl 3 140 cc/min Upper seal gas 3.0 liter/min Lower seal gas 8.0 liter/min Fiber drawing speed 200 m/min. Where "cc" stands for cubic centimeter, "min" is minute and "m" is meter. Without supplying the liquid, the fiber was coated about 60 km in length for about 5 hours. The enormously big amount of carbon particles deposited on the inner wall of the reactor vessel especially at the lower half. Eventually effective discharge of the waste gas could not be performed. Example 2 This example 2 was obtained by a method according to the present invention. A fiber was drawn and carbon-coated in the same conditions as in Example 1, in the reaction apparatus as shown in FIG. 1 using a fluorine family inert liquid without hydrogen and chlorine as the liquid. The liquid has kinetic viscosity of 13 cSt at ambient temperature and boiling temperature of about 200 degrees Celsius. The liquid was supplied intermittently at flow rate of 300 cc/min for one minute every 10 minutes. This ten minute cycle was repeated. The waste liquid was treated in the waste liquid treating apparatus 12, wherein filtering process was included. The treated liquid was recycled to the reactor vessel. Under the above described conditions, the fiber coating was continued for about 8 hours and about 100 km in length. Only a little particles remained in the reactor vessel after the operation, and a further coating operation had been possible. Example 3 This example 3 was obtained by a method according to the present invention. A fiber was drawn and carbon-coated in the same conditions as in Test 2, except that the liquid was silicone family oil with kinetic viscosity of about 100 cSt and supplied continuously at flow rate of 1 cc/min. During the coating operation of this test, no particles deposited on the inner wall at all for about 8 hours and about 100 km in length since the inner wall was always wet. The reactor was kept transparent all through the experiments. Example 4 This example 4 was obtained by a method according to the present invention. A fiber was drawn and carbon-coated in the same conditions as in Test 2 concerning the gas flow. Fiber drawing speed was 500 m/min. The fiber was drawn and coated for about 4 hours and about 120 km in length. In this Example, a reaction apparatus as shown in FIG. 2 was used. The liquid was water wherein a neutral liquid detergent on the market was added with volume ratio 10 cc of detergent per 1 liter of water. The liquid was continuously supplied by a displacement pump 14 at flow rate of 20 cc/min. The waste liquid containing the solid particles was neutralized and filtered in the waste liquid treating apparatus 12, and recycled as the liquid. As a result, no carbon particle deposit was recognized at all on the inner wall just as in Test 3. The physical properties and anti-hydrogen property of the carbon coating optical fiber was uniform and stable all through the fiber length. Example 5 This example 5 was obtained by a method according to the present invention. A fiber was drawn and carbon-coated in the same conditions as in Example 2, in the reaction apparatus as shown in FIG. 2. The reactor vessel is constructed as a dual pipe. The pressure of the outer pipe 22 was set lower than that of the inner pipe 21 in order to let the gas flow from inside to outside at all times. The outer pipe 22 forms a path for the waste. Since with this kind of construction an atmosphere in the outer pipe has little effect on that in the inner pipe (reaction area), there is an advantage that an atmosphere in the outer pipe can be determined relatively freely. However, a certain amount of particles deposit on the inner pipe wall inevitably. The common reference numerals to FIG. 2 and FIG. 1 denote the same kind of parts in both drawings, and 61 denotes a waste discharge port and 62 denotes a waste gas discharge path. A synthetic lubricant with a kinetic viscosity of about 15 cSt was used as the liquid. The liquid was supplied continuously at flow rate of 3 cc/min. The outside of the outer pipe was cooled to keep the temperature at 80 °C, with water (not shown in the drawing). The result shows that no deposit was recognized in the reactor after coating operation for about 8 hours and about 100 km, the same as in the Example 3. The reactor wall tends to be heated by a coating reaction, and the liquid flowing on the wall may generate vapor due to the heat. Therefore, it is good to cool the wall, in order to keep a stable operation and not for the vapor to affect the fiber adversely. In the aforementioned embodiments, the coating material is carbon, but the present invention can work with the other materials such as TiO 2 , TiN, Si 3 N 4 , SiC or TiC. As described above, the present invention enables continuous hermetic coating for a long duration, and contributes to improving the productivity.

Claims: A method of manufacturing a hermetically coated optical fiber comprising the steps of: melting and drawing an optical preform in a draw furnace to form a bare fiber for an optical fiber; introducing the bare fiber into a reactor vessel (2, 21); supplying a reactant gas to the reactor vessel through at least one inlet (4, 4a) located at an upstream portion of the reactor vessel; coating a thin coating layer on the bare heated fiber (1) by a thermal chemical vapor deposition (CVD) process, utilizing thermal chemical reaction caused by the heat radiated from the bare fiber and the supplied reactant gas; and drawing off the fiber through an outlet port (10); characterized by flowing a liquid (13) along the inner wall of the reactor vessel (2, 21) facing the fiber, from a reservoir (8) which is located in the upstream portion of the reactor vessel, by overflowing the liquid over a weir (81) of the reservoir, said weir being provided along the inner wall of said reactor vessel (2, 21); drawing off said liquid with particles therein generated by said thermal reaction in the reactor vessel; discharging said drawn off liquid through a discharge port (6, 61) located in a downstream portion of the reactor vessel together with the reactant gas; and separating said discharged liquid containing said particles therein from the discharged reactant gases. A method according to Claim 1, further comprising the steps of: introducing the fiber (1) into an inner chamber disposed within the reactor vessel (22), the inner chamber being defined by an inner chamber wall (21) having a plurality of openings which connect said inner chamber to a chamber defined by said inner chamber wall (21) and the inner wall of the reactor vessel (22). A method according to Claim 2 and comprising flowing a second liquid down substantially an entire surface of the inner wall of the inner chamber wall (21) facing the fiber from an upstream portion to a downstream portion. A method as in Claim 2 or Claim 3 wherein the pressure within the reactor vessel (22) is set lower than that within said inner chamber wall (21). A method according to Claim 3 and comprising diverting said second liquid flowing from said downstream portion of said inner wall of said inner chamber wall (21) such that the diverted second liquid does not contact the fiber; drawing the diverted second liquid and waste gases through at least one outlet (62) located on a side of the reactor vessel (22) and at the downstream portion of the reactor vessel; and separating the diverted second liquid from the waste reactant gas. An apparatus for manufacturing a hermetically coated optical fiber comprising: a reactor vessel (2, 21); a reactant gas introducing means (4, 4a) connected to the reactor vessel for introducing a reactant gas into said reactor vessel whereby material derived from the reactant gas is hermetically coated by chemical reaction on said optical fiber passing through said reactor vessel; and an outlet port (10) through which the fiber is drawn; characterized by liquid supplying means (7) connected to said reactor vessel and said liquid supplying means having a reservoir means (8) receiving liquid from the liquid supplying means and said reservoir means having a weir (81) provided along the circumference of the inner wall of the reactor vessel (2, 22) for supplying liquid overflowing said weir substantially to the entire surface of the inner wall of said reactor vessel from an upstream portion to a downstream portion facing said fiber; a waste gas discharge port (6, 61) arranged at a down stream of the reactor vessel for discharging waste gases and liquid; and a treating apparatus (12) provided at a downstream of the waste gas discharge port (6, 61), for separating waste liquid containing particles generated in the reactor vessel from the waste gas. An apparatus according to Claim 6, characterized by second reservoir means (86) provided below said revervoir means (8) and on said inner wall, and having a weir for supplying liquid substantially on an intire surface of said inner wall below said second reservoir means (86) by overflowing the liquid in said second reservoir means. An apparatus according to Claim 6 and further comprising distributing means (84) provided on the inner wall of the reactor vessel for re-distributing the liquid flowing down said inner wall to supply the liquid along the periphery of the inner wall which is below said distributing means. An apparatus according to any one of the Claims 6 to 8 wherein a top edge of the weir (81) is indented like saw teeth. An apparatus according to any one of Claims 6 to 8 wherein a plurality of small holes are provided circumferentially at the bottom of the weir (81) through which said liquid (13) can flow out to be supplied to said inner wall of the reactor vessel. An apparatus according to Claim 6 comprising an inner chamber disposed within the reactor vessel (22), the inner chamber being defined by an inner chamber wall (21) having a plurality of openings which connect said inner chamber to a chamber defined by said inner chamber wall (21) and the inner wall of the reactor vessel (2, 21). An apparatus according to Claim 11 and comprising a further reservoir means receiving liquid from liquid supplying means, said further reservoir means having a weir provided along the inner wall of said inner chamber wall (21) for supplying liquid overflowing said weir substantially to the entire surface of the inner wall of said inner chamber wall (21).

Inventors: AIKAWA HARUHIKO, DANZUKA TOSHI, ISHIGURO YOICHI, AIKAWA, HARUHIKO, DANZUKA, TOSHI, ISHIGURO, YOICHI, Aikawa, Haruhiko, c/o Yokohama Works of Sumitomo, Danzuka, Toshi, c/o Yokohama Works of Sumitomo, ISHIGURO, YOICHI, C/O YOKOHAMA WORKS OF SUMITOMO
Applicants: SUMITOMO ELECTRIC INDUSTRIES, SUMITOMO ELECTRIC INDUSTRIES, LIMITED
Application year: 1992
Main classification: C03C25
IPC codes: C23C16, G02B6, C03C25