Fabrication of optical waveguides using slurry deposition

Abstract

A tubular formation of particulate optical material is formed by a layer slurry deposition process which involves spraying layer after layer of slurry containing particles of the optical material onto a rotating rod-shaped bait. The composition of the slurry and particularly the index of refraction of the optical material may be varied from one layer to another or from one group of layers to another to obtain a graded or stepped refraction index profile in the formation, in an optical preform formed therefrom, and ultimately in the fiber drawn from the optical preform. The particles of the slurry are suspended in a liquid vehicle which evaporates in the spray stream or shortly after deposition, and are coated with an organic binder which holds them together in the layer and in the formation, so that the formation is self-supporting. Then, the organic binder is removed and the formation is sintered, followed by a collapse of the sintered tubular formation into the optical preform in the form of a solid rod. Then, optical fiber of the desired optical properties can be drawn from the optical preform. The associated apparatus includes a spray gun aimed at the bait rod, and a receptacle for the slurry from which the slurry is supplied to the spray gun. The bait rod is clamped in chucks and is rotated, while the spray gun moves in the axial direction of the bait rod in a plurality of passes to deposit the formation on the bait rod.