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What is Optical Fibre Preform
A fiber optic preform is a cylindrical glass rod or tube used as the starting material for manufacturing optical fibers. It serves as the precursor from which optical fibers are drawn. The process of making optical fibers involves heating the preform until it softens and then pulling it to form a thin fiber.
MCVD process refers to the improved chemical vapor deposition method, which is composed of two process steps of deposition and melt shrinkage (rod forming).
The role of fiber Optical Fibre Preform
Ensure the quality and performance of optical fiber
The quality and performance of optical fiber directly affect the stability and reliability of communication equipment and network. And the fiber optic pre-fabricated rod through high temperature and high pressure treatment, can be fiber optic core rod, cladding rod and filler three bonded together to form a whole, to ensure the quality and performance of optical fiber.
Reduce the loss of optical fiber
In the process of pulling optical fiber, the loss of optical fiber will increase because of the unevenness of the optical material. And the optical fiber prefabricated rod can pre-treat the optical material, and through the high temperature and high pressure treatment, more uniformly distributed in the fiber core rod and cladding rod, thus reducing the loss of optical fiber.
Improve the production efficiency of optical fiber
Fiber optic pre-fabricated rods can be pre-treated with optical materials and then assembled into a whole, which is convenient for subsequent operation and production. This can improve the production efficiency of optical fiber, increase production and reduce production costs.
Role of Optical Fibre Preform
Precision control
Through PCVD process, the precision control and raw material utilization rate of fiber optic prefabricated rods have inherent advantages, which is suitable for the production of fiber optic prefabricated rods core rods with complex profile structure and higher technical requirements.
Performance control
The inner layer is a high refractive index core layer, and the outer layer is a low refractive index cladding, which meets the basic conditions of light wave transmission in the core layer, thus controlling the performance of the optical fiber.
Industrial application
The industrial application of fiber optic prefabricated rods is widely used in the fields of communication, internet, broadcasting and television, which is one of the infrastructures of modern information society.
The raw materials of fiber optic preforms mainly include silicon tetrachloride, germanium tetrachloride, hydrogen, oxygen, helium and so on.
Fiber optic preform is the core raw material for manufacturing quartz series optical fibers, and the raw materials used in its preparation process have an important impact on the performance and cost of optical fibers.
Specifically, silicon tetrachloride and germanium tetrachloride are the main components of the core raw materials, which are purified and deposited under the catalytic effect of industrial gases to form high-purity quartz glass rods. Hydrogen, oxygen and helium are indispensable gas raw materials in the preparation process, of which the price of helium has risen in recent years, mainly due to the long-term reliance on imports of helium for fiber optic pre-fabricated rods, unable to self-sufficiency.
In addition, the preparation of fiber optic preforms also involves other high-end quartz tubing, such as quartz liner and casing, these materials in the fiber optic preform industry has always played a crucial role in the continuous development of the course, has become an indispensable and important basic materials in the field of optical fiber.
Fabrication of Standard Fiber Preforms
Here, we cover only the fabrication of glass preforms, and mostly on those for silica fibers. In this section, the fabrication of standard fiber preforms is explained, while special preforms for various types of specialty fibers are discussed later on.
Vapor deposition methods
Many fiber preforms are fabricated with a process called modified chemical vapor deposition (MCVD or just CVD). This method was developed for silica telecom fibers in the 1970s, with pioneering contributions from the University of Southampton (UK), Bell Telephone Laboratories (Bell Labs), and Corning. Here, a mixture of oxygen, silicon tetrachloride (SiCl4) and possibly other substances (e.g. germanium tetrachloride (GeCl4) and rare earth dopants → fiber core) is generated, and chemical reactions in the gas (e.g. combustion of hydrogen) produce a fine white "soot" of (often doped) silica which is deposited on the preform and later on sintered into a clear glass layer at ≈1500 °C. During that viscous sintering, the preform is held in a gas atmosphere, which can be oxidizing or reducing, and influences the deviation from perfect stoichiometry. The process results in a fully dense and very clear glass.
Instead of conventional MCVD, one can use plasma activated chemical vapor deposition (PCVD). The difference to MCVD is that microwaves instead of a burner are used for heating the deposition region. The deposition is slow, but very precise.
A modified method with particularly high precision is plasma impulse chemical vapor deposition (PICVD), where short microwave pulses are used.
There is also plasma-enhanced chemical vapor deposition (PECVD), operating at atmospheric pressure with fairly high deposition rate.
The general advantage of vapor deposition methods is that extremely low propagation losses down to below 0.2 dB/km can be achieved because very high-purity materials can be used and contamination is avoided. In particular, SiCl4 and GeCl4 are easily purified by distillation, as they are liquid at room temperature. Particularly when no hydrogen is present (e.g. as fuel gas), the water content of such preforms is very low, avoiding a strong loss peak at 1.4 μm, which would also affect the telecom bands (→ optical fiber communications).
The different vapor deposition methods differ in many respects, e.g. concerning the possible material purity, the degree, precision and flexibility of refractive index control, the mechanical strength of the fabricated fibers, and the deposition efficiency and speed.
Fabrication strategies
Different fabrication strategies have been developed:
● Inside vapor deposition (IVD) is the most common process. Here, the deposition of material occurs inside a rotating silica glass tube, which is heated with a slowly moving gas torch from outside to ≈ 1600 °C with a flame. The burner is continuously moved back and forth along the tube. Towards the end of the process, the gas mixture is modified to form a layer with higher refractive index, the precursor of the fiber core. Finally, the tube is collapsed by heating it to more than 2000 °C; surface tension of the glass at the inner wall drives that collapse. The special deposited glass on the inner side then forms the region which will become the fiber core.
● Outside vapor deposition (OVD) is a process where the silica soot is deposited on the outer surface of some target rod (e.g. a glass mandrel), rather than inside a tube as with MCVD. Together with the material precursors such as SiCl4, a fuel gas such as hydrogen or methane is supplied to a burner which is again moved along the rotating rod. After the deposition, which increases the rod diameter, the target rod is removed, and the preform is consolidated at ≈1800 °C in a furnace, where it is also purged with a drying gas for lowering the hydroxyl content. Outside vapor deposition is used e.g. for making multimode fibers with a pure silica core and a fluorine-doped cladding; only the cladding is made by vapor deposition.
● Vapor phase axial deposition (VAD or AVD) is similar to OVD, but again uses a modified geometry, where the deposition occurs at the end of the target rod (growth in axial direction). The rod is continuously pulled away from the burner, and very long preforms can be made. Consolidation of the material can be done in a separate zone melting process. An important difference to OVD and IVD is that the doping profile is determined only by the burner geometry, rather than by a variation of the gas mixture over time.
Each strategy may be combined with different methods of deposition, i.e., of forming the gas phase from which silica soot is generated.
In some cases, one uses an additional overcladding process. Here, one inserts the glass rod into a capillary tube (typically consisting of synthetic silica) which is then collapsed by heating, forming an additional outer layer to the original rod.
Top 7 Trends In Optical Fiber Preform Manufacturing
Enhanced purity and quality control
The purity of the glass used in optical fiber preforms directly impacts the quality and efficiency of the fiber optic cables produced. Advances in material science have led to enhanced methods of achieving higher purity silica, which reduces signal loss and allows for more reliable and faster data transmission. Manufacturers are also implementing more stringent quality control measures to ensure that each preform meets rigorous standards, thereby minimizing defects that could affect fiber performance.
Innovations in fabrication techniques
Innovations in the fabrication techniques of optical fiber preforms, such as Modified Chemical Vapor Deposition (MCVD) and Plasma Activated Chemical Vapor Deposition (PCVD), are improving the efficiency and scalability of production. These advancements not only enhance the uniformity and concentricity of the preforms but also reduce manufacturing costs and time. The ongoing development of these technologies is crucial for keeping up with the rapid demand for fiber optic cables.
Increased focus on specialty fibers
The market for specialty fibers, such as polarization-maintaining fibers and multi-core fibers, is expanding. These specialty fibers require complex preform designs and precision manufacturing techniques. Advances in this area are enabling new applications in fields like medicine, aerospace, and military, where unique optical fiber characteristics such as high-power light transmission or resistance to harsh environments are necessary.
Automation in preform manufacturing
Automation is becoming increasingly prevalent in optical fiber preform production to enhance efficiency and consistency. Automated systems are being used to control the deposition of materials, the drawing process, and even the initial inspection stages. This trend not only helps in scaling up production but also ensures that the fibers produced are of consistently high quality, crucial for maintaining the performance of optical networks.
Expansion of geographical production bases
As the global demand for optical fibers grows, companies are expanding their production bases to new geographical locations. This expansion is not only driven by the need to increase production capacity but also by the need to reduce transportation costs and improve the supply chain efficiency. By establishing production facilities closer to emerging markets, manufacturers can respond more quickly to local demands and reduce lead times.
Eco-friendly manufacturing practices
Sustainability is becoming a significant concern in all manufacturing sectors, including optical fiber preform production. Manufacturers are investing in eco-friendly technologies that reduce waste and energy consumption during the preform manufacturing process. This shift includes recycling silicon tetrachloride, a byproduct of preform manufacturing, and using renewable energy sources to power production facilities, minimizing the environmental impact of their operations.
Integration with 5g and beyond
The rollout of 5G technology and the anticipation of future communication standards are driving significant developments in optical fiber preform manufacturing. The new generation of mobile networks requires extensive fiber optic networks to support increased data loads and connectivity demands. Preform manufacturers are developing products that are compatible with these new technologies, ensuring that the optical fibers can handle higher frequencies and wider bandwidths needed for 5G and beyond.
The global fiber optic preform market size was valued at USD 4.88 billion in 2022 and is anticipated to grow at a compound annual growth rate (CAGR) of 22.6% from 2023 to 2030. The growth can be attributed to the growing popularity of high-bandwidth internet connections, healthcare industry opportunities, and telecommunication infrastructure investments, among other factors. According to the Organization for Economic Co-operation and Development (OECD), the number of fiber broadband subscriptions increased across all OECD nations by 12.3% between June 2021 and June 2022.
The fiber optic preforms make optical fibers, potentially transmitting data quickly. Optical fibers are flexible transparent fiber cables of high-quality glass, plastic, and silica that operate on total internal light reflection principles. Fiber optics are mostly used for light transmission, illumination, laser delivery systems, and flexible bundling. Intensive research and development into fiber optic technology have led to several innovations and enabled many applications for optical fibers in oil and gas, medical, utilities, and defense industries.
Telecommunication and information technology are among the major industries that rely significantly on optical fiber network infrastructure. The demand for fiber optic cables has increased with the evolving fiber-rich network infrastructure. The growing demand for high bandwidth communication is one of the prominent drivers in the fiber optic preform market.
While the myriad of innovations in the telecommunication industry have paved the way for bandwidth-intensive communication based on fiber optic networks, optical fibers are also finding applications in other industries, including oil and gas, aerospace, defense, railway, and healthcare. For instance, in August 2021, SLB launched Optiq, a Schlumberger optic solution. The product features multidomain distributed sensing capabilities for various applications and settings across the energy industry. Combined with Schlumberger's extensive digital portfolio, Optiq solutions enable continuous and immediate measurements that yield actionable insights to improve operational performance, efficiency, and environmental impact. As the technology continues to advance, researchers have launched the fifth generation of fiber optics, based on the Dense Wave Division Multiplexing (DWDM) conceptual optical solutions.
The rise in data traffic in line with the continued proliferation of tablets, smart devices, laptops, and other portable devices is anticipated to further trigger the demand for optical fiber. The market is evolving continuously, as it is a vital element of the supply chain associated with the broader optical fiber and cable industry.
The market is highly concentrated, with a few well-established and multinational players. It is equally competitive owing to the strategic initiatives these players undertake to offer advanced and innovative products. As a result, the companies often engage in mergers & acquisitions and backward integration to expand their product portfolio, widen their geographic presence, and gain a competitive advantage over their competitors. Hence, the market is witnessing high internal rivalry and competition among market incumbents.
Our Factory
Futong Group Import and Export Co., Ltd. is a subsidiary of Futong Group.
Founded in 1987 and headquartered in Hangzhou, Zhejiang Province, Futong Group Co., Ltd. (hereinafter referred to as "Futong Group"), is one of the top 500 enterprises in China and one of the top 500 private enterprises in China. It mainly dedicates in the development of electronic information, energy and power transmission technology and highly purified oxygen-free metal new material technology with more than 10000 employees.
As a builder of global information superhighway and a major provider of global Internet information basic transmission materials, Futong Group takes technological innovation and technological leadership as its competitive advantages, and takes optoelectronic composite cable, sensing optical fiber, high-temperature superconducting cable, and submarine cables as its research and development direction. As the Chinese standard setter of optical fiber preform and optical fiber technology, Futong Group has established a national enterprise technology center and a postdoctoral research workstation. It has won the second prize of National Scientific and Technological Progress Award, the first prize of Chinese Electronic Information Science and Technology Award, and the major technological invention award in national information industry.
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