PROCESS FOR FORMING A TITANIA-CONTAINING PREFORM SILICA GLASS BLANK

Abstract: The present invention is directed to a process for forming a preform suitable for consolidation to a glass blank for producing an optical waveguide fiber. The preform comprises a core portion and an inner cladding layer surrounding the core portion and contains SiO2 and TiO2. A portion of the TiO2 in the preform is in a crystalline form that is predominantly rutile. In addition to SiO2 and TiO2, the preform contains an additive compound that is preferentially sacrificed instead of TiO2 when the preform is consolidated. The process includes oxidizing Si and Ti containing compounds as well as a precursor of the additive compound to form SiO2, TiO2, and the additive compound. The preform containing these materials is then formed. In addition, the preform can be converted to a glass blank by consolidation of the preform.

Description: PROCESS FOR FORMING A TITAN1A-CONTAINING PREFORM SILICA GLASS BLANK FIELD OF INVENTION The present invention relates to optical waveguide fibers and, more particularly, to a process for forming titania-containing silica glass blanks and preforms useful for producing optical waveguide fibers BACKGROUND OF THE INVENTION Although glass is a brittle material the intrinsic strength of pristine glass optical fibers is very high, on the order of 1,000,000 psi for SιO 2 based fibers Typically, glass optical fibers fail from surface imperfections when placed under sufficient tensile stress Accordingly, much effort has been devoted to the elimination of surface flaws by careful handling during and after glass forming, by a protective plastic coating, and by various treatments to the glass surface In the latter case one method of reducing failure by surface flaws is to provide a compressive stress on the glass surface that counteracts applied tensile stresses It is well known that flaws in glass grow subcπtically prior to failuie when subjected to tensile stress in the presence of water, ammonia, or other corrosive agents This phenomenon of subcπtical crack growth in glass is known as fatigue and greatly impacts the long-term reliability of glass-based materials such as glass optical fibers Therefore, the fatigue performance of optical fiber is especially important to the design of low cost fiber cables which have fewer strength members and less environmental protection than standard optical telecommunications cables It has been known for some time that the strength of a glass body may be increased by forming its surface i egion from a glass with a thermal coefficient of expansion that is lower than the thermal coefficient of expansion of the interior glass As the combination is cooled from high temperatures, this configuration places the glass surface in compression, thereby inhibiting the formation and growth of cracks See, for example U S Patent No 3,673,049 to Griffen et al and Krohn and Cooper, "Strengthening of Glass Fibers' I, Cladding," Journal of the American Ceramic Society. 52(12) 661 -664 ( 1969) Numerous attempts have been made to create a strengthened optical fiber with such a compressive surface layer See, for example, U S Patent No. 3,884,550 to Maurer et al and MacChesney et al , "Low Loss Silica Core-Borosilicate Clad Fiber Optical Waveguide," American Ceramic Society Bulletin, 52 713 (1973) U S Patent No 4, 181,403 to Macedo refers to compression in a thin surface layer formed by "molecular stuffing" in fiber with a large optical core and very thin optical cladding Some of these attempts involved the use of a TiO 2 -Si0 2 outer layer on the fiber, as its thermal coefficient of expansion is known to be less than that of Si0 2 See, for example, U S Patent No 4, 184,860 to Schneider et al , U S Patent No 4,243,298 to Kao et al , and Japanese Patent No 1,255,795 to Taka et al U S Patent No 4, 184,860 to Schneider et al ("Schneider") describes an outer TiO 2 -SiO 2 layer with 8 weight percent TiO 7 surrounding a 15 weight percent TiO 2 layer which is heat treated (by "tempering") to devitrify and partially separate and/or crystallize This heat treatment of the 15 weight percent Ti0 2 intermediate layer is intended to raise the thermal coefficient of expansion so that it is substantially greater than the coefficient of the outer TiO 2 -Si0 2 layer, thereby putting the outer layer in compression Thus, the Schneider fiber design relies on the 8 weight percent TiO outer layer to provide enhanced strength through compression Another study involved SiO 2 -TiO 2 glasses containing 10-20 weight percent TiO 2 that were clear when formed but exhibited increased opacity from phase separation and anatase formation, along with large changes in thermal expansion, upon heat treatment at temperatures below the annealing point See "Binary Titania-Silica Glasses Containing 10 to 20 weight percent Ti0 2 ," Journal of the American Ceramic Society, 58(5-6) ( 1976) and U S Patent No 3,690,855 to Schultz ("Schultz") By studying the physical properties of these TiO 2 -SiO 2 compositions, Schultz described three glass forming regions as stable (0-10 weight percent), metastable (10-18 weight percent) and unstable (> 18 weight percent) Some recent research has been directed toward understanding the mechanism of crack growth in SiO 2 glass on the molecular level See, for example, Michalske and Bunker, "The Fracturing of Glass," Scientific American. Dec 1987, pp. 122-129 The Michalske and Bunker paper presents an atomistic study of glass fracture in the presence of water, but is limited to homogeneous SiO 2 glass Additional research has been directed toward crack growth in continuous fiber filled composites See, for example, Michalske and Hell ann, "Strength and Toughness of Continuous- Alumina Fiber-Reinforced Glass- Matrix Composites," Journal of the American Ceramic Society. 71(9) 725-31 (1988) Thus, it is known in the art that the addition of a TiO 2 -Si0 2 outer cladding layer to an optical waveguide fiber produces beneficial results A primary focus of this prior work has been increasing the fatigue resistance of the resulting optical waveguide fiber Much of this work has concentrated on the use of Ti0 2 -SiO 2 outer cladding layers of relatively high thickness, with the minimum thickness of said layers being about 1 μm For example, U S Patent No 4.243,298 to Kao et al discloses the use of 1 - 10 μm thick TiO,-Sι0 2 layers, with a preferred range of 1 -5 μm U S Patent No 4,877,306 to Kar discloses Ti0 2 -Si0 2 outer cladding layers about 2-3 μm thick Others have identified the range of 2-5 μm See, for example, U S Patent No 4,975, 102 to Edahiro et al and Oh et al , "Increased Durability of Optical Fiber Through the Use of Compressive Cladding," Optics Letters 7(5) 241 -43 (1982) U Patent No 5,067,975 to Backer et al ("Backer et al '975") expressly discloses the use of Ti0 2 -SiO, outer cladding layers in the range of about 1 -3 μm in thickness Additionally, U S Patent No 5. 140,665 to Backer et al ("Backer et al '665") claims an optical waveguide fiber with a Ti0 2 -Si0 2 outer cladding layer, including an outermost cladding layer with thicknesses of less than 3 μm, and further claims outermost cladding layer thicknesses of less than 1 μm U S Patent No 5, 180,41 1 to Backer et al ("Backer et al '41 1 "), a continuation-in-part of Backer et al '975, discloses a method for manufacturing a fatigue resistant optical waveguide fiber with a TiO 2 -SiO 2 outer cladding layer, whereby a layer of TiO 2 -SiO 2 is deposited on a doped SiO 2 preform and the resulting preform is exposed to an atmosphere containing chlorine and oxygen at a temperature of about 900° to 1400° C After consolidation, the blank is drawn into an optical waveguide fiber with inhomogeneities in its outer TiO 2 -Si0 2 layer U S Patent Nos 5,241,615 and 5,318,613 to Amos et al ("Amos et al '615" and "Amos et al '613 ") disclose an optical waveguide fiber with a very thin titania-silica outer cladding layer and a method for making it The outer cladding layer of Ti0 2 -SiOn glass has a thickness of less than 1 μm and a TiO 2 concentration that is less than or equal to about 10 weight percent The present invention is directed to an improvement upon the manufacture of optical waveguide fibers with a TiO 2 -SiO 2 glass outer cladding layer SUMMARY OF THE INVENTION The present invention relates to a process for forming a preform comprising a core portion and a cladding portion surrounding the core portion The preform is suitable for consolidation to a glass blank In this process, Si and Ti containing compounds are oxidized to form SiO 2 and TιO 2 A preform containing the SiO 2 and Ti0 2 is then formed where a portion of the Tι0 2 present in the preform is in crystalline form with the crystalline form being predominantly rutile The present invention is further directed to a process fur forming a preform comprising a core portion and a cladding portion surrounding the core portion The preform is suitable for consolidation to a glass blank This is achieved by oxidizing Si and Ti containing compounds and a precursor of an additive compound to form SiO 2 , TiO 2 and the additive compound A preform containing SiO > , TiO 2 , and the additive compound is formed where the additive compound is preferentially sacrificed instead of Ti0 2 when the preform is consolidated Also in accordance with the present invention is a process for reducing the depletion of TiO 2 from an Si0 2 -TiO 2 containing glass blank This involves oxidizing Si and Ti containing compounds and a precursor of an additive compound to form SiO 2 , TiO 2 , and the additive compound A preform containing SiO 2 , TιO 2 , and an additive compound is then formed The preform is then consolidated under conditions effective to form a glass blank The additive compound in the preform is effective to reduce the depletion of TιO 2 from the outer layer during consolidation Another aspect of the present invention relates to a process of drying a glass blank having a core portion and a cladding layer surrounding the core portion The blank contains tin oxide and is dried in the absence of chlorine gas BRIEF DESCRIPTION OF THE DRAWINGS FIG 1 graphically represents the fraction of rutile crystalline TiO 2 in the outei cladding layer of a preform versus the total concentration of deposited TiO 2 when Sn0 2 is present or absent in the preform FIGS 2 and 3 are graphs of the concentrations of oxides present in the outer cladding layers of glass blanks as a function of distance from the surface for blanks consolidated in, respectively, the absence and presence of chlorine DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to forming a preform, which comprises a core portion and an inner cladding layer surrounding the core portion The preform contains Siϋ 2 and Ti0 2 where a portion of the Ti0 2 in the preform is in a crystalline form that is predominantly rutile. The preform further comprises an additive compound that is preferentially sacrificed instead of TiO, when the preform is consolidated The presence of the additive compound in the preform causes more of the crystalline TiO 2 present in the layer to be rutile than if the additive compound were not present fhe rutile form preferably comprises at least 5 1 percent of the total crystalline TiO : in the outer cladding layer This layer has a thickness of about 0 5 μm to 10 μm, preferably about 1 μm to 2 μm TiO 2 and the additive compound can be present in any portion of the preform, permitting the replacement of GeO 2 in the preform with TiO 2 . However, it is particularly desirable to apply these materials together with SiO 2 to a porous outer cladding layer surrounding the inner cladding As a result, the portion of TiO 2 in the outer cladding layer is in a crystalline form that is predominantly rutile In addition, the additive compound present in the outer cladding layer is preferentially sacrificed instead of Ti0 2 from the outer cladding layer during consolidation The additive compound in the outer ciadding layer is a metal oxide compound, the metal being selected from the group consisting of Sn, Pb, Bi, Sb, and mixtures thereof A preferred metal oxide compound is SnO 2 , which preferably comprises about 0 1 to 10 weight percent, more preferably about 1 to 2 weight percent, of the outer cladding layer of the augmented preform A glass blank suitable for producing an optical waveguide fiber and comprising a core portion, a consolidated inner cladding layer surrounding the core portion, and a consolidated outer cladding layer surrounding the inner cladding layer can be produced by consolidating the preform. This is achieved by consolidating the preform under conditions effective to produce a glass blank Consolidation is carried out at a temperature of 900° to 1400° C in an atmosphere comprising a treating gas The treating gas comprises a gas selected from the group consisting of helium, oxygen, chlorine, and mixtures thereof The process further comprises drawing the glass blank into an optical waveguide fiber In accordance with the process of the invention, the concentration of Ti0 2 in the consolidated outer cladding layer of the glass blank is no more than about 3 weight percent less than the TiO 2 concentration in the porous outer cladding layer deposited on the preform. Preferably, the porous outer cladding layer on the preform comprises about 8 to 20 weight percent TiO 2 , and the consolidated outer cladding layer of the glass blank comprises about 5 to 17 weight percent Ti0 2 More preferably, the porous outer cladding layer comprises about I I to 13 weight percent Ti0 2 , and the consolidated outer cladding layer comprises about 8 to 10 weight percent Ti0 2 The temperature during the consolidation of the preform to the glass blank is at least 1 100°C It is instructive to consider TiO,-SiO ? compositions in four forms 1 ) bulk glass in general, 2) low density soot preforms, 3) higher density glass blanks after dehydration consolidation, and 4) optical fibers after drawing For Ti0 2 -Si0 2 compositions in general, at Ti0 2 concentrations below the eutectic (about 10 5 wt % TiO 2 ), the Ti0 2 appears to be both randomly dispersed in the Si0 2 matrix and present in clusters of 5- and 6-fold coordinated Ti ions (4-foid coordinated Ti ions are less likely to occur in clusters and are only clustered in combination with 5- or 6- fold coordinated Ti ions) As TiO 2 concentrations increase above the eutectic point, these clusters are nucleating sites for somewhat spherical phase separated regions or "inhomogeneities" which grow in size and may begin to devitrify as crystalline TiO ? In the region of maximum glass stability - below the eutectic point - these inhomogeneities have not been observed, i e . there are no significant levels of clusters greater than about 10 Angstroms in diameter, the resolution limit for a conventional Scanning Transmission Electron Microscope (STEM) instrument It is also possible to detect phase separation (i e , to distinguish an inhomogeneity from a cluster) when the inhomogeneity reaches a sufficient size that discontinuities appear in macroscopic physical properties such as thermal expansion coefficient, density, refractive index, volume of mixing, strain and anneal points as a function of concentration. Such discontinuities have been correlated classically to a transition from an amorphous to a phase separated state In Backer et al '975, it is disclosed that, after drawing at temperatures above 1900° C , optical fiber TiO 2 -SiO 2 layers are amorphous glass at TiO ? concentrations below about 1 1 weight percent However, the Ti ions are believed not to be randomly dispersed in the S() 2 matrix but clustered with other Ti ions in 5- and 6-fold coordination, the same as in bulk glasses as described above Valence bond theory suggests that it is unlikely that an isolated 5- or 6-fold coordinated Ti ion exists in the glass network, each such Ti ion would likely be linked to at least one other Ti ion, resulting in clustering It should also be noted that the coordination of the Ti ions in optical fiber may be affected by the fast quench associated with the fiber drawing process and the presence of crystalline Ti0 2 in the glass blank from which the fiber is drawn Clusters in compositions below about 1 1 weight percent TiO 2 are smaller than the critical size required for nucleation either as a separate liquid or crystalline phase in the draw process Below this TiO 2 concentration, microscopic properties of the glass network control the mechanical performance of the resulting fibers, while above this level, "macroscopic" effects due to phase separation and crystallization determine the fibers' mechanical performance In addition, dehydration/consolidation in C 1 2 increases the crystallization in the glass blank from which fibers are drawn, and such fibers appear to have a greater degree of phase separation For compositions below about 1 1 weight percent Ti0 2 , and in the homogeneous glass matrix for higher TiO 2 compositions, it is believed that the enhanced fatigue resistance of Ti0 2 -SiO 2 over SiO 2 may be explained by reference to bond force constants rather than bond energy, and by reference to the strong likelihood of clustered Ti ions in the glass Considering the bond energy alone, TiO 2 -SiO 2 compositions would appear to be weaker than pure SiO 2 , as the Ti-O bond strength as reported in the literature is on the order of 70 Kcal/mole, compared with 1 10 Kcal/mole for the Si-O bond. However, consideration of bond force constants leads to a very different result In TiO 2 -SiO 2 compositions, regardless of the Ti ion coordination, there are numerous Ti-O-Si linkages Compared to Si-O linkage, the oxygen atom in a Ti-O-Si linkage resides in a more asymmetric, broadened potential well Such broadening makes many more vibrational states accessible to the system, in effect making the system as a whole "softer" Because of the looseness of this array relative to the more rigid Si-O-Si environment, the Ti-O-Si linkages formed as a result of Ti0 2 addition will function as high energy dissipating regions to remove energy at the stress point of the crack tip Clustering of 5- and 6-fold coordinated Ti ions would result in even greater enhancement of fatigue resistance and extended regions of enhanced energy dissipation in the glass, as the potential wells for ^Si- O- v Ti and IV Si-O- vl Ti linkages would be even more asymmetric than for , Si-0- lv Ti, and, therefore, the system would be even "softer" At compositions above around 1 1 weight percent Ti0 2 , where phase separated TiO ? -Si0 2 becomes visible, the Ti-O-Si linkages within each phase domain and the Ti-O-Si linkages forming the interface between the Ti0 2 -rich inhomogeneity and the SiO 2 -rich matrix are very important to enhanced fatigue resistance It appears that, for Ti0 -Si0 2 bulk glass in general at Ti0 2 concentrations above the eutectic point, the composition of the phase separated domains or inhomogeneities is approximately me same, viz 92- 95 weight percent TiO ? in at least an 1 1 weight percent Ti0 2 matrix It is conceivable that the matrix concentration could be as high as 19 weight percent TiO 2 For TiO 2 concentrations below about 19 weight percent, the number of inhomogeneities are believed to increase with increasing overall TiO 2 concentration, but the size and composition remain approximately the same Similarly, the concentration of TiO 2 dissolved as clustered Ti below the inhomogeneity size threshold in the Si0 2 -rich matrix stabilizes at a maximum near the eutectic bulk composition at 1 1-1 weight percent TiO 2 The structure and composition of the soot as laid down, and of the glass blank after dehydration/consolidation are discussed below In the drawn fiber, for the concentration regions studied, the proportion of inhomogeneities may increase to more than 50 volume percent During the draw process, the large TiO 2 crystals in the glass blank dissolve into a TiO 2 -Si0 2 melt at temperatures above about 1900° C , and subsequently precipitate out as much smaller phase separated domains or inhomogeneities in the quenched fiber as the fiber rapidly cools to below about 1550° C In the drawn fiber, a substantial portion of the observed inhomogeneities are between 10 and 100 Angstroms in diameter, typically approximately 30-50 Angstroms For inhomogeneities of this scale, the composition of each phase region cannot be measured even by electron microscopy techniques In the drawn fiber, the generally observed inhomogeneities appear to be phase separated regions without substantial crystal content As described above, one aspect of the present invention relates to processes for manufacturing optical fiber with Ti0 2 -Si0 2 outer claddings The methods of the invention are particularly suitable for use with the outside vapor deoosition (OVD) and the vapor axial deposition (VAD) soot laydown processes OVD processes are described in U.S Patent No 4.453.961 to Berkey and further described in U S Patent Number 4,486,212 to Berkey, the disclosures of which are hereby incorporated by reference VAD processes are described in Optical Fiber Communications, vol 1 , 1985, Bell Telephone Laboratories, Inc. section 3.3, pp 100-1 16, and in U S Patent No 4,367,085, the disclosures of which are hereby incorporated by reference Typically, an additional laydown of one or more Ti0 2 -SiO : soot layers is provided at the end of a conventional OVD soot laydown process In one embodiment, this additional laydown step is included in the process for manufacturing a single unitary soot preform with a core region and a cladding region, as described in U S Patent No 4,486,212 to Berkey In another embodiment, the additional laydown step is provided at the end of an overcladding process such as is also described in U S Patent No 4,486,212 to Berkey, whereby a large diameter intermediate fiber comprising the core region and a portion of the cladding region is overcoated with additional cladding soot It is known in the art that OVD and VAD soot laydown may be carried out with a plurality of burners as described in U.S Patent No 4.684,384 to Berkey and U S Patent Nos 4,378,985 and 4,568,370 to Powers. The additional laydown of a TiO 2 -Si0 2 layer is carried out as follows The SiCl 4 vapor is provided to the burner by a reactant delivery system of the type described in U S Patent No 4,314,837 to Blankenship In addition, the TιCl 4 vapor is provided to the burner by a flash vaporization system as described in U S Patent No 5 078,092 to Antos et al SιO 2 soot consists of agglomerates of glass soot particles with a diameter in the range of about 0 1 to 0 3 μm It is believed that TιO 2 -SiO 2 soot exists in three separate forms a) agglomerates of particles of roughly homogeneous solutions of TιO 2 in SιO 2 , with about the same diameter as SιO 2 soot particles, b) tiny crystalline fines on the surface of these particles, typically less than about 90 Angstroms in diameter (these fines being more prevalent in compositions with greater than about 10 5 weight percent Tι0 2 ) and c) larger crystals agglomerated with the particles typically between 200 and 1,000 Angstroms in diameter It is theorized that the TιCl 4 and SιCl 4 react at approximately the same temperature in the flame, forming the roughly homogeneous glass particles, except where the TιCI 4 can react with H 7 O at temperatuies less than approximately 1600° C As the solubility limit of TιO 2 in SιO 2 is exceeded the fines of TιO 2 may be precipitated from the molten particles The larger crystals may be formed bv the reaction of TιCl 4 with H 2 O at temperatures less than about 1600" C in the coolei center ne of the burner flame After laydown, the soot preforms can be dehydrated and consolidated, typically in an atmosphere containing a drying agent such as chlorine, as described in U S Patent No 3,933,454 to DeLuca, U S Patent No 4 125 388 to Powers, and U S Patent No 4,741,748 to Lane et al , the disclosuies of which are hereby incorporated by reference The dehydration and consolidation steps can be carried out simultaneously or in two different steps, piovided that rewetting of the dehydrated preform is avoided by the use of a dry inert gas atmosphere or other means In an alternative embodiment, the deposition of the outer cladding laver can be carried out after the dehydration/consolidation of the rest of the preform, and the resultant preform with a soot outer cladding layer can be thereafter dehydrated and consolidated TιO 2 can exist in two crystalline forms anatase and rutile Anatase is the low temperature form, and rutile is the higher density, high tempeiature polymorph The transformation from anatase to rutile is irreversible and with a reagent grade powdei proceeds to completion at a temperature below 1000"C as reported in Rao, Can J Chem 29 498-500 ( 1961), which is hereby incorporated by teference - I I - Without the inclusion of an additional metal oxide such as tin oxide in the outer metal cladding layer, the principal form of crystalline titania in the porous outer cladding layer of the preform is anatase. However, the introduction of such metal oxides modifies the crystalline form of titania crystals during laydown. As a result, when tin is present in the porous outer cladding layer, the principal form of crystalline titania is rutile Consolidation of an optical waveguide glass blank having an SiO 2 -Ti0 2 outer cladding layer with a TiO 2 concentration in the range of 8- 16 weight percent, is generally carried out above 1400°C, a temperature at which one could reasonably assume that the crystalline TiO 2 in the cladding layer is completely converted from anatase to rutile. This, however, has been found not to be the case; complete conversion of anatase to rutile Ti0 2 in an Si0 2 -Ti0 2 cladding layer requires temperatures above 1500°C Thus, the presence of Si0 2 appears to have an inhibiting effect on the anatase-rutile transformation Although applicants do not wish to be bound by theoretical considerations, they believe that this inhibiting effect is caused by the formation of a solid solution in which Si atoms are interstitially incorporated into the TiO, anatase lattice. Applicants have now unexpectedly found that the inhibitory effect of Si0 2 on the TiO 2 anatase-rutile transformation can be substantially ameliorated by the inclusion of certain metal oxide precursors in the reactant stream used to form the porous outer layer of a preform for a glass blank. For example, if SnO is deposited along with Si0 2 and Ti0 7 in this porous layer, the rate of anatase-to-rutile Ti0 2 conversion is enhanced by an order of magnitude. In addition to compounds of Sn, other compounds useful for promoting anatase-rutile conversion in the course of glass blank consolidation include precursors of the oxides of Pb, Bi, Sb, and mixtures thereof. In addition to its promoting effect on anatase-rutile Ti0 2 conversion, the inclusion of a SnO 2 precursor in the outer layer reactant stream has an additional, perhaps related, benefit. Consolidation of the preform to the glass blank in the presence of SnO results in the loss of substantially less TiO 2 from the SiO 2 -TiO 2 outer cladding layer than if SnO 2 were not present Thus, during consolidation at temperatures at about 1 100°C and above, the SnO 2 present is sacrificially lost in preference to Ti0 2 . In fact, following consolidation, substantially no SnO 2 remains in the glass blank While not wishing to be bound by theory, it is believed that the large size of anatase crystals enhances their reactivity with chlorine, producing volatile titanium compounds that are carried away in the exhaust gases By contrast, rutile crystals have smaller surface areas, which makes them less susceptible to reaction with chlorine Still a further unexpected advantage has been found stemming from the use of an SnO 2 precursor in the fabrication of glass blanks in accordance with the present invention Included in the consolidation process is a drying phase that reduces the OH content of the preform Drying is typically achieved by the inclusion of a drying gas, preferably chlorine, in the consolidation gas atmosphere, which typically also contains helium However, applicants have discovered that Sn0 2 acts as a drying agent, allowing consolidation of a preform to a blank in an atmosphere containing only helium As noted above, the predominant crystalline form of titania in the consolidated glass blank of the present invention is rutile During fiber drawing, all crystalline forms of titania are converted to an amorphous state However, the resulting optical fibers produced in accordance with the present invention show unexpectedly improved fatigue resistance The following examples further illustrate the invention EXAMPLES Example 1 — Effect of Tin Oxide On Anatase-Rutile Conversion Of TiO 2 To quantify the effect of SnO 2 on the anatase-rutile conversion of TiO 2 , a series of soot preforms were prepared from a reaction stream containing SiCI 4 and TiCl 4 The resulting preforms contained a total concentration of about 5 to 18 weight percent TiO 2 A second series of soot preforms was prepared, similar to the first except that sufficient SnCl 4 was included in the reaction stream to yield two weight percent SnO 2 in each of the preforms The concentration of the rutile form as a fraction of the total crystalline TiO 2 in the preforms was determined by X-ray diffraction FIG 1 graphically displays the results of this work Tne weight fraction of rutile as a function of total TiO 2 content was a sigmoidal relationship The rutile fraction for low and high TiO 2 concentrations asymptotically approached zero and one, respectively A possible mechanism for the transformation of anatase to rutile can be described as a two step process. The first step involves the direct transformation of anatase (A) to rutile (R) at a rate described by the constant K,. ( 1 ) In Equation ( 1 ), it is assumed that the reaction depends only on the original concentration of titania, which will be represented by [AJ. The concentration of anatase and rutile as a function of time will be represented by [A] and f A -[A], respectively Equation (1 ) simply means that the larger the initial concentration of anatase the more likely rutile can be formed Thermodynamically, rutile is more stable than anatase; the direction of the reaction is always to the right. The second process step is transformation of anatase to rutile represented by Equation (2). To obtain A + R „ 2 R ( 2 ) the kinetics solution, the rate equation for the reactions of anatase must be defined. Afterwards, this equation is integrated, and the rate constants are determined by fitting the fractional rutile concentration to the integrated rate equation solution. The rate equation for anatase is given by: d[ A] = _ς [ A] « ■ K 2 [ A] [R] = Jϊ j ] + K 2 [ A] { [A o ] - [ A] } ( 3 ) t This equation can be integrated by rearranging Equation (3) into the form given by [A] f [dA] t-t ) (4; K 2 { [A o ] [A] ) [A] where t and t„ arc the final and initial times of the reaction The solution to Equation (4) is given by the following equation If one rearranges equation (5) and solves for f A], one finds that where the initial time t 0 is assumed to be zero To solve the concentration of rutile [R], the identity that [R] equals J [A -[A] } and the fractional rutile concentration are used to obtain the fraction given by the rutile concentration divided by the sum of the anatase and rutile concentrations This ratio is given in Equation (7) [ R] ^ ( 1 " e ~t G > 1 ) [R] + [A] (K, + K 2 [ A o ] e - where G is given by (K,+K 2 [A 0 ]) The time for the runs was three hours This is equivalent to 10,800 seconds This time period will be the fixed time in Equation (7) When the weight fraction [A equals zero and 1, the fractional concentration of rutile asymptotically approaches zero and 1, respectively Therefore, Equation (7) correctly describes the apparent form of the data Fitting the data obtained to Equation (7), the following rate constants K, and K 2 in the absence and presence of SnO 2 were determined SnO 2 K, (Sec^ 1 ) K 2 (Sec ) Absent 2.38xl0 "7 5 όx l O "1 Present 2 01 x 10 " * 6 3X10 "1 Thus, the limiting step in the reaction kinetics is that shown in Equation ( 1), which is controlled by the K, rate constant. The presence of tin helps transform anatase to rutile by a rate constant an order of magnitude larger than when tin is absent The K 2 rate constants for tin present or absent are almost identical, which shows that tin has little effect in changing the reaction kinetics as described by Equation (2) Example 2 - Variations in Dopant and Burner Gas Flows in Fabricating Soot Preforms The following describes the equipment and conditions under which soot preforms were fabricated to produce the data displayed in FIG. 1 Two series of preforms were prepared Members of the first series had various levels of TiO,, and each member of the second series contained two weight percent SnO, in addition to Tiϋ 2 A series of dopant and burner gas flows were used to simulate a range of temperatures that might be encountered in the deposition of titania-doped silica coatings on optical wave guide (OWG) fiber blanks The delivery system consisted of three heated bubblers containing the reactants SiCl 4 at 43 °C, TiCl 4 at 84°C, and SnCI 4 at 55 °C Oxygen was bubbled through the liquids via Tylan Mass Flow controllers controlled by an LBM-PC/XT Flow settings for the dopants were held constant at 1 5 1/min, 1 45 1/min, and 0 15 1/min for SiCI , TiCI , and SnCl 4 , respectively The highly focused burner gas flows were also controlled by the computer and were linearly increased during deposition in three ranges 6-1 1 1/min, 7-12 1/min, and 8-13 1/min The premix oxygen to methane gas ratios of 0 7, 0 8, 0 9, and 0 97 were varied for each of the three ramp conditions This represented three temperature ranges and four flame oxidation conditions. Lower burner gas flow rates and higher premix ratios (higher oxidizing conditions) appeared to improve the TiO, deposition rate The inner shield, outer shields, and extra oxygen gas flows were held constant at 2 5, 3 6, and I 0 1/min, respectively Ramping of the premix gases was employed to achieve a suitable density that would prevent the preforms from splitting Preform fabrication consisted of the deposition of titania doped or tin-titania doped silica by flame hydrolysis on a 1/2" tapered alumina bait rod with a 0 002 inch/inch taper This allowed easier bait removal after the preform had cooled The alumina bait rods were initially preheated for 20 min, which cleaned and fire polished them and removed any foreign material that might have been present Gas flows for this part of the process were nominally 10 1/min and 9 7 1/min for methane and oxygen, respectively A carbon deposit was then applied to the bait rod using an acetylene torch, which was accomplished by holding the acetylene torch stationary under the bait as it traversed for 6 to 10 cycles of the 20" deposition distance while traveling at 2 5 crn/sec and rotating at 200 rpm Both rotation and traversing, speed and direction were controlled by Compumotor 2100 controllers in a stand alone mode Prior to the start of the deposition phase of the process, oxygen was bubbled through the dopants at the prescribed flows for 20 to 30 minutes to allow the temperature to stabilize An additional 5 minutes of mixing through the burner was also allowed before the traverse was started Depositions lasted 3 hours The preforms were then removed from the bait and placed in a holding oven at 125 °C with a nitrogen purge until consolidated. The soot preforms were consolidated for 3 hours and 20 minutes in a helium atmosphere (40 1/min ) at a furnace set point of 1510°C Down feed through the hot zone was maintained at 5 0 mm/min The concentration of TiO, and the crystalline phases of TiO, in the soot preforms were measured by wet chemical and x-ray analysis, respectively FIG 1 displays the amount of rutile (R) TiO 2 as a fraction of rutile (R) plus anatase (A) crystalline TiO 2 (R (R + A)) present in the performs versus the total weight percentage of deposited TiO, when SnO, is present or absent in the preforms For a given total concentration of TiO, in the deposited soot, the presence of Sn0 2 results in the formation of substantially increased amounts of rutile crystalline TiO, in the SiO,-Ti0 outer cladding layer The promoting effect of SnO 2 on the transformation of anatase to rutile crystalline TiO, in the presence of SiO, was the conclusion of the kinetics measurements discussed above Example 3 - Fabrication of Preforms Using TiO, and SnO, Precursors at Various Concentrations Preforms were fabricated using a silica core glass deposited prior to the deposition of the titania-tin layers, thus simulating the overcladding procedure normally found in the standard OWG process This process utilized a 1/4" O D tapered alumina bait, rotating at 200 rpm, on which a deposition of SiO, soot measuring 30 mm in diameter and 50 cm in length was formed over a period of 2 5 hours The bait traverse speed was 2 54 cm/sec The SiO, source material was SiCl 4 heated to 43 °C Oxygen was bubbled through the SiCI 4 liquid at various rates to generate a constant mass of 7 26 gpm (grams/minute) The dopants were routed to a manifold forming the final vapor stream, which was fed to a highly focused burner with a fume tube diameter of 089 in Delivery line temperatures were maintained at 125 °C to prevent condensation of the dopants in the delivery lines After the initial completion of a 2 5 hour deposition of SiO,, the combination of SnCl 4 and TiCl 4 vapors were simultaneously routed into the delivery line with the SiCl 4 vapor No attempt was made to move the burner off the preform prior to the introduction of the tin and titania to allow for equilibration The SnC^ liquid was heated to 55 °C, and oxygen was passed through the liquid at a flow rate of from 0.148 to 0 741 1pm (liters/minute) The TiCI 4 was heated to 83 °C, and an oxygen gas flow was fed through it at a constant flow rate of 1.224 1pm The SiCI 4 oxygen flow was decreased from its starting flow of 1 886 Ipm at the end of the SiO 2 overclad period to as low as 1 414 1pm, which corresponded to 10% SnO 2 , 15% TiO 2 , and 75% SiO, in the flame The dopant oxygen gas flows were controlled by Tylan Mass Flow Controllers, which themselves were controlled by an IBM/PC XT computer The highly focused burner gas flows were also controlled via the computer and mass flow controllers The premix gas and oxygen were programmed to increase at one second intervals, linearly starting out at 6 1pm CH 4 and ending at 1 1 1pm over the deposition period The premix oxygen increased at an equivalent rate, maintaining an oxygen to gas ratio of 0 97 to the CH 4 flow, this corresponds to an overall increase of from 5 82 to 10 67 1pm for the premix oxygen The burner inner-shield, outer-shield and fume tube oxygen were held constant at 2 5, 3 6 and 1 0 Ipm, respectively Example 4 - Consolidation of Preforms with and without Chlorine in Consolidation Atmosphere Following the procedure described in Example 3, two samples of preforms were prepared from each of a series of compositions containing 15 weight percent TiO, and 2- 10 weight percent SnO, One sample was consolidated in a helium (40 1pm) muffle atmosphere, while the other was consolidated in a muffle atmosphere containing 40 1pm helium and 0 4 1pm Cl 2 Both consolidations were carried out at 1510°C, as monitored outside the quartz muffle, the actual preform temperature under these conditions was about 1425 °C Under either set of atmospheric conditions, the preforms were held in the upper zone of the consolidation furnace for 40 minutes prior to being lowered into the hot zone at 5 mm/min At the end of the down-feed cycle, another 10 minute hold was initiated before the consolidated blank was withdrawn from the furnace at 35 mm/min and cooled to room temperature FIGS. 2 and 3 graphically present microprobe analytical data obtained from preforms containing 15 weight percent TiO 2 and 6 weight percent SnO 2 that had been consolidated in, respectively, the absence and presence of chlorine FIG 2, which plots the weight percentages of the oxides as a function of distance from the surface for the blank consolidated in the no-chlorine atmosphere, shows that, on average, about 2 weight percent SnO 2 remained in the consolidated blank FIG 3, which displays the oxide contents of the blank that had been consolidated with chlorine present, shows no detectable amount (< 0 1 weight percent) of SnO 2 remaining in the blank Apparently, the chlorine in the consolidation atmosphere accelerated the depletion of SnO 2 from the blank. For the lower starting concentrations (2-4 weight percent) of SnO, in the preforms, SnO, removal from the blank was substantially complete in both the chlorine- absent and chlorine-present consolidation atmospheres Example 5 - Effect of SnO, on Depletion of TiO, from the Outer Cladding Layer of a Blank A series of preforms prepared as described in Example 3 and containing about 1 1 weight percent TiO, and 2-8 weight percent SnO, were consolidated in 1 percent chlorine in helium atmosphere, as described in Example 4 A loss of 1-2 weight percent TiO, in the outer cladding layer of the blank from the amounts originally present in the preforms resulted from the consolidation process Under the same conditions, there was a 4-8 weight percent depletion in TiO 2 in the outer cladding layer when no SnO 2 was present in the preform Because SnO, acts as a drying agent, consolidation of SnO 2 containing preforms to glass blanks can be accomplished in a chlorine-free atmosphere Chlorine can attack TiO, to produce volatile migrating species, so consolidation in an inert atmosphere such as helium in the absence of chlorine may be advantageous. Example 6 - Fatigue Resistance of Fiber Obtained from SnO, - Containing Augmented Preform A fiber was drawn from a blank obtained by consolidation of a preform having an outer layer produced by a 30-minute deposition of soot containing 10 weight percent TiO 2 and 2 weight percent SnO,. Tensile strength measurements made on short gauge lengths of fiber showed fatigue resistance "n" values of 32-35 (this parameter is discussed in Backer et al., '975 and in Glaesemann et al., "Strength Variability of Indented Soda-Lime Glass," J. American Ceramic Society. 70:441 -44 (1987). Using 10-m lengths of fibers, "n" values between 47 and 60, with a mean of 53, were obtained The invention has been described in detail for the purpose of illustration, but it is understood that such detail is solely for that purpose, and variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the following claims.

Claims: WHAT IS CLAIMED: 1 A process of forming a preform comprising a core portion and a cladding portion surrounding the core portion, said preform being suitable for consolidation to a glass blank for producing an optical waveguide fiber, said process comprising oxidizing Si and Ti containing compounds to form SiO 2 and TiO 2 and forming a preform containing the SiO, and the TiO 2 , wherein a portion of the TiO 2 present in the preform is in crystalline form with the crystalline form being predominantly rutile 2 A process according to claim 1 , wherein the preform is prepared by the process comprising providing a preform having a core portion and an inner cladding layer portion surrounding said core portion; and carrying out said oxidizing and said forming to deposit on said inner cladding layer a porous outer layer comprising Si0 2 and Ti0 2 , wherein a portion of the TiO, present in said outer cladding layer is in crystalline form with the crystalline form being predominantly rutile 3 A process according to claim 2 further comprising consolidating said preform, after said carrying out said oxidizing and said forming, under conditions effective to form said preform a glass blank 4 A process according to claim 3, wherein said consolidating is carried out under at least one of the conditions comprising an atmosphere comprising a treating gas, or wherein said treating gas comprises helium, or oxygen, or chlorine 5 A process for forming a preform comprising a core portion and a cladding portion surrounding the core portion, said preform being suitable for consolidation to a glass blank for producing an optical waveguide fiber, and said process comprising oxidizing Si and Ti containing compounds and a precursor of an additive compound to form SiO 2 , TiO 2 , and the additive compound and forming the preform containing the SiO 2 , the TiO 2 , and the additive compound, wherein the additive compound is preferentially sacrificed instead of TiO 2 when consolidating said preform. A process according to claim 5, wherein said treating gas comprises chlorine. 6 A process according to claim 5, wherein the glass blank is prepared by the process comprising: providing a preform having a core portion and an inner cladding layer surrounding said core portion; carrying out said oxidizing and said forming to deposit on said innei cladding layer a porous outer cladding layer comprising SiO 2 , TiO,, and an additive compound preferentially sacrificed instead of TiO, when consolidating said preform 7. A process for reducing depletion of TiO, from an SiO,-TiO 2 containing glass blank during formation of said glass blank from a preform, comprising oxidizing Si and Ti containing compounds and a precursor of an additive compound to form SiO,-Ti0 2 and the additive compound; forming a preform containing the SiO,, the TiO,, and the additive compound; and consolidating the preform under conditions effective to form a glass blank, wherein said additive compound is effective to reduce depletion of TiO, during said consolidating. 8. A process according to claim 16, wherein the preform is prepared by the process comprising: providing a preform having a core portion and an inner cladding layer surrounding said core portion; and carrying out said oxidizing and said forming to deposit on said inner cladding layer a porous outer cladding layer comprising SiO 2 , TiO 2 , and an additive compound, wherein said consolidating is conducted under conditions effective to form a glass blank, wherein said additive compound is effective to reduce depletion of TiO 2 from said outer layer during said consolidating A process according to claim 2, wherein said porous outer cladding layer further comprises an additive compound preferentially sacrificed instead of TiO 2 during said consolidating 9 A process according to claim 1 , 5 or 7, wherein the additive compound is a metal oxide compound, said metal being selected from the group consisting of Sn, Pb, Bi, Sb, and mixtures thereof, and/or said metal oxide compound is SnO 2 10 A process according to claim 2, 6 or 8 wherein said depositing is caried out by an outside vapor deposition process or a vapor axial deposition process 1 1 A process according to claim 1 , 5, or 7 wherein said metal oxide compound is SnO 2 or SnO 2 comprising about 0 1 to 10 weight percent of said porous outer cladding layer, or SnO 2 comprising about 1 to 2 weight percent of said porous outer cladding layer 12 A process according to claim 8, wherein the outer cladding layer of said glass blank has a TiO 2 concentration no more than about 3 weight percent less than the TiO 2 concentration of said porous outer cladding layer of said preform 13. A method according to claim 1,5, or 7 wherein said porous outer cladding layer of said preform comprises about 8 to 20 weight percent TiO,, and said outer cladding layer of said glass blank comprises about 5 to 17 weight percent TiO 2 or wherein said porous outer cladding layer of said preform comprises about 1 1 to 13 weight percent TiO 2 , and said outer cladding layer of said glass blank comprises about 8 to 10 weight percent TiO 2 14 A process according to claim 2, 6, or 8 wherein said consolidating is carried out at a temperature of 900° to 1400°C

Inventors: BURKE GERALD E, TRUESDALE CARLTON M, BURKE, GERALD, E., TRUESDALE, CARLTON, M.
Applicants: BURKE GERALD E, CORNING INC, TRUESDALE CARLTON M, BURKE, GERALD, E., CORNING INCORPORATED, TRUESDALE, CARLTON, M.
Application year: 1997
Main classification: C03C
IPC codes: C03B37, C03C3, C03C13, G02B6