CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to and benefit under 35 U.S.C.

§ 119(e) of United States Provisional Patent Application No. 63/027,685 filed May 20, 2020 entitled "Applying Metal Coatings to Optical Fibers via a Conductive Polymer Coating followed by a Metal Coating," and to USSN 17/240,083 filed April 26, 2021 entitled "Applying Protective Coatings to Optical Fibers", the contents of which are hereby incorporated by reference in their entireties for all purposes.

STATEMENT AS TO RIGHTS TO APPLICATIONS MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0002] This invention was made with Government support under

Contract No. DE-AC52-07NA27344 awarded by the United States Department of Energy. The Government has certain rights in the invention.

BACKGROUND

Field of Endeavor

[0003] The present writing relates to optical fibers and more particularly applying protective coatings to optical fibers including a conductive polymer coating and another coating.

State of Technology

[0004] This section provides background information related to the present disclosure which is not necessarily prior art. [0005] Scratches to optical fibers drastically reduce their mechanical strength, so optical fibers are encased in some form of protective coating to prevent scratching. These coatings are typically organic polymers. These polymer coatings are typically applied in line during fiber production, immediately after a glass preform is drawn into a fiber. This is accomplished by pulling the fiber through a liquid monomer solution, which adheres to the fiber and is then cured either by exposure to UV light or heat. While these coatings are robust in benign environments, they degrade at elevated temperatures and are unstable in many corrosive environments. Furthermore, they are thermally insulating, which can lead to challenges in situations where control of fiber temperature by either active heating or cooling is important.

SUMMARY

[0006] Features and advantages of the disclosed apparatus, systems, and methods will become apparent from the following description. This description, which includes drawings and examples of specific embodiments, provides a broad representation of the apparatus, systems, and methods. Various changes and modifications within the scope of the writing will become apparent to those skilled in the art from this description and by practice of the apparatus, systems, and methods. The scope of the apparatus, systems, and methods is not intended to be limited to the particular forms disclosed and this writing covers all modifications, equivalents, and alternatives falling within the scope of the apparatus, systems, and methods as defined by the claims.

[0007] The herein apparatus, systems, and methods provide a multi-layer coating on a glass optical fiber consisting of an inner conductive polymer layer and at least one outer protective layer. The herein apparatus, systems, and methods have use by manufacturers of components for fiber-interfaced packages and optical fiber fabricators.

[0008] In various embodiments the herein apparatus, systems, and methods include two major steps. First, a conductive polymer coating is applied to the optical fiber as it is being produced. Second, a protective coating is applied to that conductive polymer coating. In other embodiments additional layers, including metal layers, are applied. The conductive polymer coating is applied immediately after the fiber is drawn from preform to fiber.

[0009] The apparatus, systems, and methods are susceptible to modifications and alternative forms. Specific embodiments are shown by way of example. It is to be understood that the apparatus, systems, and methods are not limited to the particular forms disclosed. The apparatus, systems, and methods cover all modifications, equivalents, and alternatives falling within the scope of this writing as defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS [0010] The accompanying drawings, which are incorporated into and constitute a part of the specification, illustrate specific embodiments of the apparatus, systems, and methods and, together with the general description given above, and the detailed description of the specific embodiments, serve to explain the principles of the apparatus, systems, and methods.

[0011] FIG. 1 illustrates one embodiment of the apparatus, systems, and methods.

[0012] FIG. 2 provides further details of the apparatus, systems, and methods 100 illustrated in FIG. 1. [0013] FIG. 3 illustrates another embodiment of the apparatus, systems, and methods.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS [0014] Referring to the drawings, to the following detailed description, and to incorporated materials, detailed information about the apparatus, systems, and methods is provided including the description of specific embodiments. The detailed description serves to explain the principles of the apparatus, systems, and methods. The apparatus, systems, and methods are susceptible to modifications and alternative forms. This writing is not limited to the particular forms disclosed. This writing covers all modifications, equivalents, and alternatives falling within the scope of the apparatus,

[0015] Referring to the drawings and in particular to FIG. 1, one embodiment of the apparatus, systems, and methods is illustrated. This embodiment is designated generally by the reference numeral 100. The embodiment 100 includes the structural elements identified and described below. Reference numeral 102 - Fiber with conductive polymer coating,

Reference numeral 104 - Fiber,

Reference numeral 106 - Furnace,

Reference numeral 108 - Coating die,

Reference numeral 110 - Liquid monomer/liquid suspension,

Reference numeral 112 - Liquid monomer coated on fiber,

Reference numeral 114 - Bank of UV lamps or Furnace, and Reference numeral 116 - Polymerized/consolidated coating.

[0016] The structural elements of the system 100 having been identified and described the operation of the system 100 will now be considered. First, the starting preform glass (not shown) is drawn to a fiber 104 by passing it through a furnace 106 under tension on a draw tower. Below the furnace 106 sits a coating die 108 filled with a liquid monomer 110. In an alternative embodiment the coating die 108 is filled with a liquid suspension of the desired conductive polymer. The fiber 104 is drawn through this die 108, leaving a coating 112 of the liquid monomer (or suspension) 110 on the fiber 102. The coating 112 is then polymerized/consolidated by passing it through a bank of UV lamps or furnace 114, producing a continuous coating of conducting polymer 116. In another embodiment the coating 116 is polymerized/consolidated by passing through a f a bank of UV lamps or furnace 114. This results in a length of optical fiber 102 coated with a protective coating 116.

[0017] FIG. 2 provides further details of the apparatus, systems, and methods 100 illustrated in FIG. 1. FIG. 2 is a schematic depiction illustrating further details of the apparatus, systems, and methods 100. FIG. 2 includes the structural elements identified and described below.

Reference numeral 202 - Fiber,

Reference numeral 204 - Metal salt,

Reference numeral 206 - Aqueous solution,

Reference numeral 208 - Electroplating chamber,

Reference numeral 210 - Power supply,

Reference numeral 212 - conductive polymer coating,

Reference numeral 214 - Counter electrode (anode), and Reference numeral 216 - Metal coating.

[0018] The structural elements of the apparatus and, systems having been identified and described, the operation of the apparatus, systems, and methods will now be considered. A polymer coating 212 is applied to the fiber 202. An outer metal coating is then applied to the conductive polymer coating. This is accomplished using an electroplating chamber 208. A metal salt 204 is dissolved in an aqueous solution 206, and the fiber 202 is inserted into the solution 206. The choice of metal salt or multiple metal salts determines the composition of the metal coating, and other electroplating parameters such as supporting electrolytes and additives determine the morphology of the coating. The electroplating setup consists of a power supply 210, a counter electrode (anode) 214, and a voltage applied between the counter electrode 214 and the polymer- coated fiber 202. The voltage causes reduction of the metal ions on the surface of the conductive polymer coating 212, plating a metal coating 216 on the outside of the fiber 202. The voltage can be applied because the conductive polymer coating 212 of the fiber 202 is sufficiently conductive to act as an electrode in the electroplating solution. An embodiment of the electroplated metal 216 illustrated in FIG. 2 is copper. Another embodiment of the electroplated metal 216 is gold. Yet another embodiment of the electroplated metal 216 is silver. Still another embodiment of the electroplated metal 216 is nickel. Another embodiment of the electroplated metal 216 is tin. Another embodiment of the electroplated metal 216 is chromium. In various other embodiments the electroplated metal 216 is other metals and alloys. This plating step can be done either by submerging the entire fiber at once or by drawing the fiber through the plating solution, either in-line with the entire fabrication process or after the tower draw as a separate step. Electroplating is a relatively fast deposition process, with deposition rates on the order of a micrometer per minute. Due to the metal coating thickness required for the fiber 202, i.e., tens of micrometers, very short electroplating times are required. [0019] Referring to FIG. 3, another embodiment of the apparatus, systems, and methods is illustrated. This embodiment is designated generally by the reference numeral 300. The embodiment 300 includes the structural elements identified and described below.

Reference numeral 302 - Preform glass,

Reference numeral 304 - Furnace Reference numeral 306 - Uncoated Fiber

Reference numeral 308 - Coating die filled with liquid monomer (additional embodiment a polymer suspension)

Reference numeral 310 - Coating of liquid monomer on the surface of the fiber

Reference numeral 312 - Furnace or UV lamps Reference numeral 314 - Fiber coated with conducting polymer Reference numeral 316 - Electroplating chamber Reference numeral 318 - fiber pulling apparatus Reference numeral 320 - metal coated optical fiber Reference numeral 322 - spool of coated fiber [0020] The structural elements of the embodiment of the apparatus, systems, and methods 300 having been identified and described the operation of the embodiment 300 will now be considered. First, the starting preform glass 302 is drawn to a fiber 306 by passing it through a furnace 304 under tension from a fiber pulling mechanism 318 in a draw tower. Below the furnace 304 sits a coating die 308 filled with a liquid monomer. In another embodiment the coating die 308 is filled with a liquid suspension of the desired conductive polymer. The fiber 306 is drawn through this die 308, leaving a coating 310 of the liquid monomer (or suspension) on the fiber 306. The coating 310 is then polymerized/consolidated by passing through a bank of UV lamps 312. In another embodiment the coating 310 is polymerized/consolidated by passing through a furnace 312. This results in the optical fiber 302 being coated with a conductive polymer protective coating 314. This coated fiber then enters an electroplating chamber 316 similar to the one described in FIG. 2. In this chamber, the fiber is passed through a metal salt solution (not shown) and a metal coating is deposited on the fiber. The metal- and conductive polymer- coated fiber 320 is removed from the electroplating chamber and collected on a spool 322.

[0021] Although the description above contains many details and specifics, these should not be construed as limiting the scope of this writing but as merely providing illustrations of some of the presently preferred embodiments of the apparatus, systems, and methods. Other implementations, enhancements and variations can be made based on what is described and illustrated in this patent document. The features of the embodiments described herein may be combined in all possible combinations of methods, apparatus, modules, systems, and computer program products. Certain features that are described in this patent document in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments.

[0022] Therefore, it will be appreciated that the scope of the present writing fully encompasses other embodiments which may become obvious to those skilled in the art. In the claims, reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more." All structural and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device to address each and every problem sought to be solved by the present apparatus, systems, and methods, for it to be encompassed by the present claims. Furthermore, no element or component in the present disclosure is intended to be dedicated to the public regardless of whether the element or component is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase "means for."

[0023] While the apparatus, systems, and methods may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that this writing is not intended to be limited to the particular forms disclosed. Rather, the writing is to cover all modifications, equivalents, and alternatives falling within the scope of the writing as defined by the following appended claims.

[0024] Broadly, this writing discloses apparatus, systems, and methods that provide coats on a glass optical fiber including an inner layer and an outer layer. The method can include two steps. First, a conductive polymer coating is applied to the optical fiber as it is being produced. Second, a protective coating is applied to that conductive polymer coating. The conductive polymer coating is applied immediately after the fiber is drawn from preform to fiber.

[0025] This writing discloses at least the following implementations.

[0026] A first implementation presented is an apparatus for making an optical fiber, comprising: a starting preform glass, a fiber draw tower for drawing said starting preform glass into a fiber, a coating die containing a liquid monomer, or a liquid suspension wherein said fiber is drawn through said coating die leaving said liquid monomer or said liquid suspension as a coating on said fiber, and a bank of ultraviolet lamps or a furnace wherein said fiber with said liquid monomer or said liquid suspension as a coating is drawn into said ultraviolet lamps or said furnace and polymerized or consolidated by said ultraviolet lamps or said furnace and results in said fiber being coated with a conductive polymer protective coating.

[0027] As a further implementation of the preceding or following implementations to the extent not incompatible there is a chamber containing metal in a solution wherein said fiber coated with a conductive polymer protective coating is drawn through said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a metal coating.

[0028] As a further implementation of the preceding or following implementations to the extent not incompatible said coating die contains said liquid monomer.

[0029] As a further implementation of the preceding or following implementations to the extent not incompatible said coating die contains said liquid suspension.

[0030] A further implementation presented herein is an apparatus for making an optical fiber, comprising: a starting preform glass, a fiber draw tower for drawing said starting preform glass into a fiber, a coating die containing a liquid monomer, or a liquid suspension wherein said fiber is drawn through said coating die leaving said liquid monomer or said liquid suspension as a coating on said fiber, a bank of ultraviolet lamps or a furnace wherein said fiber with said liquid monomer or said liquid suspension as a coating is drawn into said ultraviolet lamps or said furnace and polymerized or consolidated by said ultraviolet lamps or said furnace and results in said fiber being coated with a conductive polymer protective coating, and an electroplating chamber containing a metal salt dissolved in an aqueous solution wherein said fiber coated with a conductive polymer protective coating is inserted into said electroplating chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a metal coating. [0031] A further implementation presented herein is an apparatus for making an optical fiber, comprising: a starting preform glass, a fiber draw tower for drawing said starting preform glass into a fiber, a coating die containing a liquid monomer, or a liquid suspension wherein said fiber is drawn through said coating die leaving said liquid monomer or said liquid suspension as a coating on said fiber, a bank of ultraviolet lamps or a furnace wherein said fiber with said liquid monomer or said liquid suspension as a coating is drawn into said ultraviolet lamps or said furnace and polymerized or consolidated by said ultraviolet lamps or said furnace and results in said fiber being coated with a conductive polymer protective coating, and an electroplating chamber containing a metal salt dissolved in a non- aqueous solution wherein said fiber coated with a conductive polymer protective coating is inserted into said electroplating chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a metal coating.

[0032] As a further implementation of the preceding or following implementations to the extent not incompatible said coating die only contains said liquid monomer.

[0033] As a further implementation of the preceding or following implementations to the extent not incompatible said coating die only contains said liquid suspension. [0034] As a further implementation of the preceding or following implementations to the extent not incompatible said fiber with said liquid monomer or said liquid suspension as a coating is only drawn into said ultraviolet lamps.

[0035] As a further implementation disclosed herein is a method of making an optical fiber, comprising the steps of: providing a starting preform glass, using a fiber draw tower for drawing said starting preform glass into a fiber, drawing said fiber through a coating die containing a liquid monomer or a liquid suspension wherein said liquid monomer or said liquid suspension is left as a coating on said fiber, and drawing said fiber with a liquid monomer or liquid suspension as a coating through a bank of ultraviolet lamps or a furnace wherein said fiber with said liquid monomer or said liquid suspension as a coating is drawn into said ultraviolet lamps or said furnace and polymerized or consolidated by said ultraviolet lamps or said furnace and results in said fiber being coated with a conductive polymer protective coating.

[0036] As a further implementation of the preceding or following implementations to the extent not incompatible further comprising the step of inserting said fiber coated with a conductive polymer protective coating into a chamber containing metal in a solution resulting in said fiber coated with a conductive polymer protective coating being coated with a metal coating. [0037] As a further implementation of the preceding or following implementations to the extent not incompatible said coating die only contains said liquid monomer.

[0038] As a further implementation of the preceding or following implementations to the extent not incompatible said coating die only contains said liquid suspension.

[0039] As a further implementation of the preceding or following implementations to the extent not incompatible, said fiber with said liquid monomer or said liquid suspension as a coating is only drawn into said ultraviolet lamps.

[0040] As a further implementation of the preceding or following implementations to the extent not incompatible, said fiber with said liquid monomer or said liquid suspension as a coating is only drawn into said furnace.

[0041] As a further implementation of the preceding or following implementations to the extent not incompatible said fiber coated with a conductive polymer protective coating is inserted into said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a copper metal coating.

[0042] As a further implementation of the preceding or following implementations to the extent not incompatible said fiber coated with a conductive polymer protective coating is inserted into said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a gold metal coating.

[0043] As a further implementation of the preceding or following implementations to the extent not incompatible said fiber coated with a conductive polymer protective coating is inserted into said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a silver metal coating.

[0044] As a further implementation of the preceding or following implementations to the extent not incompatible, said fiber coated with a conductive polymer protective coating is inserted into said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a nickel metal coating.

[0045] As a further implementation of the preceding or following implementations to the extent not incompatible, said fiber coated with a conductive polymer protective coating is inserted into said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a tin metal coating.

[0046] As a further implementation of the preceding or following implementations to the extent not incompatible, said fiber coated with a conductive polymer protective coating is inserted into said chamber resulting in said fiber coated with a conductive polymer protective coating being coated with a chromium metal coating. [0047] The foregoing description of the technology presented herein, has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the technology to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments disclosed are meant only to explain the principles of the technology and its practical application to thereby enable others skilled in the art to best use the technology in various embodiments and with various modifications suited to the particular use contemplated. The scope of the technology is to be defined by the following claims.

[0048] All elements, parts, and steps described herein are preferably included. It is to be understood that any of these elements, parts and steps may be replaced by other elements, parts, and steps or deleted altogether as will be obvious to those skilled in the art.

[0049] It is possible that in the examination and ultimate allowance of this writing as a patent, some text may have been omitted by requirement of the jurisdiction examining this writing. In interpreting this writing, the original text without deletions is to be used.

[0050] Amendments, alterations, or characterizations made in order to expedite allowance are to be considered to have been made without any prejudice, waiver, disclaimer, or estoppel, and without forfeiture or dedication to the public of any subject matter as originally presented.

[0051] Reviewers of this writing or any related writing, shall not reasonably infer any disclaimers or disavowals of any subject matter as originally contained herein. To the extent any amendments, alterations, characterizations, or other assertions previously made in this or in any related writing with respect to any art, prior or otherwise, could be construed as a disclaimer of any subject matter supported by the original writing herein, any such disclaimer is hereby rescinded and retracted.