105 heat resistant Plastic Optical Fiber Cable optimized for the MOST system

105 heat resistant Plastic Optical Fiber Cable optimized for the MOST system MOST Interconnectivity Conference 5 th Nov. 2008, @Seoul Marriott hotel Kazuki NAKAMURA Yoshihiro TSUKAMOTO Mitsubishi Rayon Co, Ltd. Optical fiber Dept. http://www.pofeska.com/

Outline About Mitsubishi Rayon Motivation for the development Target requirements Performance data Summary

Mitsubishi Rayon as POF supplier 1975 1980 1985 1990 1995 2000 2005 2008 Dupont Mitsubishi Rayon: ESKA Asahi Chemical Electronics Toray Hächst Mitsubishi Rayon has more than 30 years, longest history supplying Plastic Optical fibers highest share of the global Plastic Optical Fiber market with wide range of applications highest market share of the automotive network market of the MOST systems

Variety of Applications Optical Switch Digital audio/home networking Lighting & Illumination Automotive networking Host computer NC PC Factory level Cell level PC PLC DCS Field level Photo-electric switch Industrial lighting for machine vision Field-Bus, Machine Control

Cost down potential of technology Temperature stability >> 85 C Motivation for the development Media comparison among POF, PCS, UTP and STP Active components (FOT, Magnetics) for >> 85 Bandwidth Bending radius, ease of installation Power budget/signal Quality/EMC@Bandwidth Diagnosis, Fault detection, Repair Over all sum Cable Type Fiber Copper Characteristics POF PCS UTP STP Scalability, Usability-over-cost in other automotive applications Source; MOST Interconnectivity conference, Experience and Future scenarios by BMW AG POF for automotive, temperature limitation is, and has been always thought to be a concern Mitsubishi Rayon continue to challenge for improvement of temperature limit above 85 C to cast aside such concerns, with success for non-automotive applications and soon automotive For this specific case, the technology fits the optimized cable system for the MOST requirement

Design of Plastic Optical fiber Core: PMMA (refractive index = 1.492) Cladding: Fluorinated polymer (Lower index = ~1.402) Light propagation 1.0 mm Refractive index

Design concepts and requirements Design changes Fiber Replacing cladding to high Tg, where present cladding can not survive over 85 C in long term (multiple thousands hours) Stay with same PMMA core (Tg: ~110 C) which should be good enough for 105 C Jacketing Selected new outer sheath instead of soft Poly Amide (PA), that also influences long term stability beyond 85 C For inner sheath, stay with PA12 to maintain weld-ability with plastic ferrule made from PA12 Key parameters Aging stability of cable attenuation Thermal shrinkage and pistoning Material dependent chemical & mechanical characteristics

Requirements Based on present 85 requirement Test Guidelines for fiber Optic Cable / Prufrichtlinie fur LWL-Meterware Optical loss:105 /5,000hrs. @650nm: <200dB/km Stripping force (Inner-jacket from fiber): >50N Pistoning @105 /24hrs: <±30μm Thermal shrinkage @105 /24hrs: <0.6% Bending loss: the smaller the better Material: Bending stiffness (influence handling harness fabrication) Non-flammability, modified DIN 72551-5 Hydrolysis 1.51mm 1.00mm Inner Sheath: un-strippable from fiber 2.30mm Fiber with new cladding Outer Sheath: strippable from inner sheath

Summary Test Results 105 Aging Stripping force Core to Inner to Inner Outer Pistoning Core to Inner to Inner Outer Shrinkage Nonflammability Bending Stiffness PASS (3000h) PASS PASS PASS PASS PASS PASS PASS Aging test ongoing up to 5,000hrs!

Loss spectrum Attenuation [db/m] 0.7 0.6 0.5 0.4 0.3 0.2 Exisiting cable 85C-1 85C-2 85C-3 85C-4 85C-5 Requirement Attenuation [db/m] 0.7 0.6 0.5 0.4 0.3 0.2 105 resistant cable 105C-1 105C-2 105C-3 105C-4 105C-5 Requirement 0.1 0.1 0 600 620 640 660 680 700 Wave length [nm] 0 600 620 640 660 680 700 Wave length [nm] Similar to existing product, attributed to common core material

105 aging 1000 Attenuation [db/km@650nm] 900 800 700 600 500 400 300 200 100 Existing product 105 resistant cable 0 1000 2000 3000 4000 5000 Aging Time [hrs] Loss at 650nm maintain low level up to 3000hrs The test is ongoing up to 5000hrs

Pistoning of fiber from inner-sheath 40 30 Pistonning [μm] 20 10 0-10 -20-30 -40 105 resistant cable Tested at 105 Present product Tested at 90 0 10 20 30 40 50 Aging Time [hrs] Conform the requirement at 105

Shrinkage [%] 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Thermal shrinkage of cable 105 resistant cable Tested at 105 Requirement Present 85 cable Tested at 85 0 10 20 30 40 50 Aging Time [hrs] Conform the requirement even at 105

Induced loss(db) 6.0 5.0 4.0 3.0 2.0 1.0 0.0 Static bending Present product 105 resistant cable Required upper limit 0 10 20 30 40 50 60 Bending Radius(mm) Bending loss is even lower than present product

30 Bending stiffness 25 Stress (N) 20 15 10 Present product 105 resistant cable 5 0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 Displacement (mm) Similar to present product

Extinguish time[sec] Non-flammability Test procedure: 2.5.1 PN 5.1 Test Guidelines for fiber Optic Cable, According to DIN 72551-5 Extinguish time until the flame goes out. 35 30 25 20 15 10 5 0 Present product Stable non-flammability sample number = 10 105 resistant cable 0 1 2 3

Hydrolysis No change observed in appearance after 85 95%RH. 720hrs treatment

Bandwidth 140 Present product Bandwidth (MHz*20m) 120 100 80 60 40 MOST Requirement > 50MHz 105 C cable 20 0 0 1 2 3 4 5 6 7 Sample Number Negligible difference of bandwidth caused by replacement of cladding

Summary Sample 105 Aging Stripping force Fiber/Inner Pistoning Fiber/inner Shrinkage Flame Retardance Bending Stiffness 105 resistant 170dB/km at 3000h 54N 9μm 0.57% PASS (10/10) 17N Requirement >200dB/km @105 5000hrs >50N >30μm @105 48hrs >0.6% @105 48hr s <30sec. 10 to 18N Supposed critical parameters are conformed by newly designed POF cable Target release date: middle of 2009

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