Optical Fibre Manufacturing Process

2Cl2
SiO2
GeO2

GeCl4
O2

SiCl 4

1 Raw Materials 2 Deposition

The raw materials used in the initial stages An oxy-hydrogen burner heats a section of the rotating quartz
of optical fibre manufacture include high substrate tube to 1700 °C. This creates a radial reaction zone where
quality synthetic quartz substrate tubes, the oxidation of the halides occurs. The silicon dioxide (SiO 2) and
ultra-pure halides such as silicon germanuim dioxide (GeO2) particles are deposited in the inside of
tetrachloride (SiCl 4) and germanium the tube, downstream from the burner, by a process known as
tetrachloride (GeCl4), as well as the gaseous thermophoresis. Chlorine which acts as a drying agent, is produced
forms of pure oxygen (O2), Helium (He), as a waste product. As the burner repeatedly passes over the tube,
Chlorine (Cl2), Sulphurhexafluoride (SF6 ) it sinters and melts the layers of sooty particles into successive layers
and Nitrogen. of glass. In the final few layers, the concentration of germanuim
dioxide (GeO2) is increased, thereby creating a region of higher
It is important that the above materials are refractive index that will become the fibre core.
free from foreign articles, and contain very
low concentrations (<5 ppm) of water
molecules.

Optical Fibre Cable

Manufacturing Process
Optical fibres in a cable are normally protected in one of two
ways, either being tight buffered or contained in loose tubes.
When tight buffered the individual optical fibre is covered
directly with a layer of thermoplastic material or one or more
fibres can be contained within a loose tube which is filled
with a thixotropic gel. These processes are performed on
specially equipped extrusion lines.

The tight buffered fibres or loose tubes are then stranded, SZ-stranding
mostly incorporating aramid yarn as tensile strength members
and a glass reinforced polymer (GRP) rod as central strength
members. SZ or conventional concentric stranders are used for
Simplex
this process. Interstices (open spaces) can be filled with petroleum cable
jelly (PJ) or dry water swellable materials may be incorporated
to protect against water penetration in the final cable. The
stranded assembly is then sheathed (covered with a layer of Distribution
polyethylene or other polymer material) on an extrusion line. cable
For specific purposes an additional layer of material can be
added such as aramid yarn for additional strength or a Mineshaft
corrugated steel tape for increased mechanical protection cable
(e.g. rodent proofing). Low Count
Duct cable
Test and measurement of cable parameters are conducted at Heavy Duty
various stages of production and prior to despatch to the Duct cable
Long Span
customer. Aerial cable
3 Collapse 4 Sleeving
Once the required number of layers of In order to increase the length of fibre that can be
glass with the appropriate refractive index drawn cost effectively from a single preform, the
have been deposited and sintered by the preform volume is increased by sleeving. This is done
burner, the tube is collapsed to form a by inserting the preform into a thick syntetic quartz
solid glass rod called a preform. glass tube. The two are then fused together at
2000 °C using an oxy-hydrogen ring burner, which
moves vertically upwards.

Optical Fibre
and Cable Testing
Performance verification forms an integral part of the manufacturing
of optical fibre. The capability of each length of optical fibre to meet
the required optical, geometrical, mechanical and dispersion
characteristics is determined for each length of fibre before it is cabled.
The optical attenuation is rechecked after cabling, in order to verify
that it has not been significantly altered by the cabling process.

The capability of the cable to withstand the rigours of installation and Weight
use are determined using a wide range of mechanical tests that include tolerance
bending, flexing, torsion, impact resistance and crush tests. This is done
using specially designed equipment that simulates field conditions
according to international standards. Special emphasis is placed on
tensile strength and environmental performance. ATC uses a holistic
approach to achieve an integrated cable/clamping system for aerial Bending
self-supporting cables. Special test facilities and test methods are used
to ensure long-term system reliability. Crush tests

Environmental
conditions
 5 1
Optical Fibre Drawing
Singlemode
Optical fibre is drawn by inserting the 9.5/125/245
preform into a high temperature graphite
resistance furnace at 2100 °C. Argon and 2
nitrogen gases provide an inert atmosphere
to prevent oxidation of the graphite. A
laminar, filtered airflow ensures that the
preform surface remains clean.
1. Furnace
2. Laser diameter
The furnace is located at the top of the measurement
tower in a Class 100 clean room
environment. The latter is very important
3 (125 µm)
3. Cooling tube
as any particles that adhere to the optical 4. Acrylate coating
fibre during the drawing process may act applicator
as a defect centre for crack propagation, (190 µm)
causing the fibre to break. 5. UV lamps
6. Acrylate coating
The preform's tip softens in the furnace applicator
and is drawn down to a 125 µm diameter 4 (245 µm)
7. UV lamps
optical fibre in a free-flow process (no dies
are used). The core to cladding ratio is
maintained from the preform to the fibre.
The optical fibre is cooled in a helium
cooling tube and coated with dual layers
of ultraviolet radiation cured acrylate resin,
which provide protection against
mechanical damage and moisture ingress. 5
For identification purposes, optical fibres
are coloured either by inking or by
pigmentation in the coating process during
fibre drawing.

Corrugated Steel Tape

Armoured cable

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