Abstract: A method of forming features on substrates by imprinting is provided. The method comprises: (a) forming a polymer solution comprising at least one polymer dissolved in at least one polymerizable monomer; and (b) depositing the polymer solution on a substrate to form a liquid film thereon; and then either: (c) curing the liquid film by causing the monomer(s) to polymerize and optionally cross-linking the polymer(s) to thereby form a polymer film, the polymer film having a glass transition temperature (Tg); and imprinting the polymer film with a mold having a desired pattern to form a corresponding negative pattern in the polymer film, or (d) imprinting the liquid film with the mold and curing it to form the polymer film. The temperature of imprinting is as little as 10° C. above the Tg, or even less if the film is in the liquid state. The pressure of the imprinting can be within the range of 100 to 500 psi.

Abstract: A method of making an optical component wherein an optical component carrier is introduced through an opening (2) into a mold (1). The carrier is aligned relative to the mold (1) by means of at least one positioning means. A removable closure member (4) is introduced into a coupling portion of the mold to form an optical window surface (3). A light transmissive moldable material is filled into the mold (1) and cured. The closure member (4) is then removed to complete the optical component.

Abstract: A capillary optic produced by impression has a mold with an external profile figured for radiation transmission along an axis used as a mandrel for impression. The mold often takes the form of a precisely etched wire. At least one soft plate is used for impressing the mold into the soft plate. The mold is removed from the soft plate to leave a vacant impression figured for radiation transmission in the soft plate along an axis. The impression is then closed to provide for radiation transmission along the axis of the impression. In the most common embodiment, two relatively soft plates having identical compositions with flat and highly polished initial surfaces are used. The impression(s) can be coated with reflective materials. Disclosure of an optical connector and emitter is included.

Abstract: An apparatus for manufacturing a light guide in a liquid crystal display and a manufacturing method thereof with a simplified mold structure. In the apparatus, an core material portion is fixed to a light guide molding stamper to constitute a molding device along with the stamper. A fixing member fixes the stamper to the core material portion. The molding device constitutes a mold for molding the light guide, along with a stationary core and a movable core. Accordingly, the stamper and the molding core are integrally formed and sealed, so that a mold structure can be simplified and stable manufacturing of the light guide can be provided.

Abstract: The present invention provides a process for producing a polymer optical waveguide, comprising the steps of: preparing a mold comprising a concave portion; bringing a substrate into contact with the mold, filling the concave portion with a core-forming curable resin; curing the core-forming curable resin in the concave portion; removing the mold from the substrate; and forming a clad layer on the substrate; wherein the mold comprises a cured resin layer and a reinforcing member, the cured resin layer has the concave portion, the reinforcing member has an introduction portion which communicates with the concave portion and an injection inlet which communicates with the introduction portion, and a discharge portion which communicates with the concave portion is provided in the reinforcing member, the cured resin layer and/or a space between the cured resin layer and the reinforcing member, and a resin injecting device which is used in the process.

Abstract: A production method of a light guide and a stamper, combining anisotropic etching and isotropic etching. First a plurality of microstructures is formed on a back surface and a front surface of the substrate. By electroforming, rear and front stampers are made from the back and front surfaces of the substrate. Light guides are produced using the rear and front stampers. Anisotropic etching is performed on the front surface of the substrate, forming V-shaped, U-shaped or pyramid like microstructures. Isotropic etching is performed on the back surface of the substrate, forming quadratic, bowl like, oval or semicircular microstructures. If a transparent substrate is used, then after finishing the etching of microstructures, a light source, a reflector, a diffusion sheet and a prism sheet are added, simulating a back light module for performing a test of luminosity, uniformity of light intensity and light emission angle, so that optical properties are known before proceeding with inverse-forming of the stampers.

Abstract: One embodiment of a back lighting apparatus of a liquid crystal display apparatus includes a light source for generating light, a plurality of optical fibers having both ends optically connected with the light source and a part of the optical fibers attached to the back surface of the liquid crystal display panel. Each optical fiber has one or more diffusion lines for scattering light from the light source to a pixel line of the liquid crystal display panel, thereby lighting the entire portion of the back surface of the liquid crystal display panel. The apparatus has a support plate for fixing the optical fibers to the back surface of the liquid crystal display panel, and an optical diffusing unit for optically connecting the light source to the optical fibers. The present invention can improve the resolution of a liquid crystal display apparatus and allow implementation of a 3D image.

Abstract: A process for producing a polymer optical waveguide, including the steps of: preparing a mold;

Abstract: The invention relates to a method for producing a light guide or optical light outcoupling element with a light outcoupling surface which has light outcoupling structures by means of an injection-molding process. The light outcoupling structures are produced by means of laser ablation of the injection mold or of the already injection-molded light guide or light outcoupling element.

Abstract: A process for producing a polymer optical waveguide in which all of one or a plurality of start points and all of one or a plurality of end points of a wave guide are uniformly aligned along a same single straight line. The process comprises the steps of: preparing a mold comprising a concave portion for forming a core; bringing a cladding substrate into close contact with the mold disposing a concave portion toward the cladding substrate; filling the concave portion of the mold with a core-forming curable resin; curing the core-forming curable resin in the concave portion to form a core; and cutting a cladding substrate possessing a core part and a cladding layer thereon along the same single straight line.

Abstract: An end face of a plastic optical fiber end is treated so as not to extrude to the core side face when the plastic optical fiber end is softened and fused. The core end face of the plastic optical fiber end is pressed intermittently on a mold that is heated to a certain temperature to soften and fuse the core end face to thereby transfer the transfer face of the mold on the core end face.

Abstract: A method for fabricating large aperture optical fiber preform using a sintering apparatus for gel tube, includes the steps of: forming a uniform sol by mixing/dispersing for mixing fumed silica with deionized water, and adding a dispersing additive to form uniform sol; injecting the sol into a mold with a certain tubular form, and then gellifying the sol; demolding the tube-shaped gel from the mold; drying the tube-shaped gel; processing (or Binder burn-out & Purification) organic compounds including remaining moisture, alkali metallic impurities, and hydroxides in the gel; inserting a primary preform into the tube-shaped gel and then fastening the preform; and after arranging the gel with the primary preform therein into a sintering apparatus, sintering/over cladding the gel with the primary preform therein under vacuum atmosphere at high temperature.

Abstract: The present invention discloses A method for producing a dot-printless light guide plate for a liquid crystal display device using an addition polymerized norbornene copolymer represented by the following general formula (1): wherein R1, R2, R3 and R4 are respectively a hydrogen atom, a C1˜C10 linear, branched or cyclic alkyl group, or —COOR7 in which R7 is a C1˜C10 linear, branched or cyclic alkyl group; R5 and R6 are respectively a hydrogen atom or a C1˜C10 linear, branched or cyclic alkyl group; and x is an integer of 0 to 4.

Abstract: The invention provides a method for producing a polymer optical waveguide equipped with a plurality of alignment marks (AM), which comprises bringing a film substrate into contact with a mold having concave portions corresponding to convex portions for the optical waveguide and convex portions for a plurality of AMs, introducing a curable resin from an end of the mold into concave portions, curing the resin, peeling the mold, and forming a cladding layer on a core/AM-forming surface, or bringing a film substrate into contact with the mold having concave portions corresponding to convex portions for the optical waveguide and notches, introducing the curable resin from an end of the mold into the concave portion, curing the resin, applying a material for AM to the film substrate through the notches and, thereafter, forming the cladding layer on the core/AM-forming surface.

Abstract: A process for producing a plastic optical member is provided that includes injecting a polymerizable monomer composition into a hollow plastic tube and polymerizing the composition within the hollow tube, wherein prior to injecting the composition one end of the hollow tube is sealed with a resin. The resin may have a composition different from that of the plastic forming the hollow tube. A process for producing a plastic optical fiber base material is also provided that includes injecting a polymerizable monomer composition into a hollow plastic tube and polymerizing the composition within the hollow tube, wherein prior to injecting the composition one end of the hollow tube is sealed with a resin. Furthermore, a process for producing a plastic optical fiber is provided that includes drawing the plastic optical fiber base material obtained by the above process. Moreover, also provided are a plastic optical member and a plastic optical fiber, which are produced by the above processes.

Abstract: A process for producing a polymer optical waveguide including the steps of: preparing a mold by applying a mold-forming resin layer onto a master template, peeling the layer from the master template to obtain a template, and cutting both ends of the template to expose a concave portion; bringing the mold into close contact with a film used for a cladding layer; introducing, by capillarity, a UV-curable resin or heat-curable resin by contacting the resin with one end of the mold; curing the introduced resin and removing the mold from the film; and forming a cladding layer on film on which the core has been formed, wherein a sectional area, a sectional shape, or both of a sectional area and a sectional shape of the core changes in a longitudinal direction of the core, and both end faces of the core have different areas.

Abstract: Disclosed herein is a method of producing an object having a refractive index which varies radially from the central portion of the object toward the peripheral portion thereof. Also, an object produced by the method and an apparatus for carrying out the method are disclosed. The method comprises the steps of mounting in a rotatable reactor a solid central rotating body formed by polymerizing a first component; filling a liquid second component in the rotatable reactor around the central rotating body; rotating the central rotating body and/or the rotatable reactor to subject the first component to a dissolution, diffusion, and radial mixing into the second component; and polymerizing the dissolved first component and the second component.

Abstract: Elastomeric stamps facilitate direct patterning of electrical, biological, chemical, and mechanical materials. A thin film of material is deposited on a substrate. The deposited material, either originally present as a liquid or subsequently liquefied, is patterned by embossing at low pressure using an elastomeric stamp having a raised pattern. The patterned liquid is then cured to form a functional layer. The deposition, embossing, and curing steps may be repeated numerous times with the same or different liquids, and in two or three dimensions. The various deposited layers may, for example, have varying electrical characteristics, interacting so as to produce an integrated electronic component.

Abstract: A lightguide having either a built-in prism sheet or a built-in diffuser sheet is disclosed. The lightguide includes: a prism sheet having a plane surface and a surface with a plurality of patterned microlens; a transparent wedge having a cross-section of trapezoid; and a binder layer sandwiched between said plane surface of said prism sheet and said transparent wedge. A method for manufacturing the lightguide is also disclosed here.

Abstract: A method of manufacturing light guide by filling a polymer tube with a monomeric mixture then pressurising and heating the full length of the polymer tube to initiate and maintain polymerisation in the tube. An apparatus for performing the method is also described in which the polymer tube is placed in a reaction vessel and a temperature controlled fluid is circulated to regulate the temperature in the vessel.

Abstract: A method of preparing a planar optical waveguide assembly, comprising the steps of: (i) applying a silicone composition to a surface of a substrate to form a silicone film; (ii) exposing at least one selected region of the silicone film to radiation having a wavelength of from 150 to 800 nm to produce a partially exposed film having at least one exposed region and at least one non-exposed region; (iii) removing the non-exposed region of the partially exposed film with a developing solvent to form a patterned film; and (iv) heating the patterned film for an amount of time sufficient to form at least one silicone core having a refractive index of from 1.3 to 1.7 at 23° C. for light having a wavelength of 589 nm; wherein the substrate has a refractive index less than the refractive index of the silicone core. A planar optical waveguide assembly prepared according to the method of the invention.

Abstract: An apparatus for manufacturing a light guide in a liquid crystal display and a manufacturing method thereof with a simplified mold structure. In the apparatus, an core material portion is fixed to a light guide molding stamper to constitute a molding device along with the stamper. A fixing member fixes the stamper to the core material portion. The molding device constitutes a mold for molding the light guide, along with a stationary core and a movable core. Accordingly, the stamper and the molding core are integrally formed and sealed, so that a mold structure can be simplified and stable manufacturing of the light guide can be provided.

Abstract: Proposed is a waveguide which is formed on a substrate (2) of a polymer. For that purpose, provided between the substrate (2) and the waveguide layer (1) is an intermediate layer (8) of an inorganic material which prevents a substantial amount of energy from penetrating into the relatively highly absorbent polymer material. That minimises the waveguide losses.

Abstract: A method of fabricating a polymer part having a negative thermal expansion coefficient includes injecting a thermotropic polymer under controlled temperature and pressure conditions into a mold having an injection inlet substantially equal to the thickness of the part and a length that causes elongation of the polymer.

Abstract: The invention involves providing a microstructured fiber having a core region, a cladding region, and one or more axially oriented elements (e.g., capillary air holes) in the cladding region. A portion of the microstructured fiber is then treated, e.g., by heating and stretching the fiber, such that at least one feature of the fiber microstructure is modified along the propagation direction, e.g., the outer diameter of the fiber gets smaller, the axially oriented elements get smaller, or the axially oriented elements collapse. The treatment is selected to provide a resultant fiber length that exhibits particular properties, e.g., mode contraction leading to soliton generation, or mode expansion. Advantageously, the overall fiber length is designed to readily couple to a standard transmission fiber, i.e., the core sizes at the ends of the length are similar to a standard fiber, which allows efficient coupling of light into the microstructured fiber length.

Abstract: The invention involves providing a microstructured fiber having a core region, a cladding region, and one or more axially oriented elements (e.g., capillary air holes) in the cladding region. A portion of the microstructured fiber is then treated, e.g., by heating and stretching the fiber, such that at least one feature of the fiber microstructure is modified along the propagation direction, e.g., the outer diameter of the fiber gets smaller, the axially oriented elements get smaller, or the axially oriented elements collapse. The treatment is selected to provide a resultant fiber length that exhibits particular properties, e.g., mode contraction leading to soliton generation, or mode expansion. Advantageously, the overall fiber length is designed to readily couple to a standard transmission fiber, i.e., the core sizes at the ends of the length are similar to a standard fiber, which allows efficient coupling of light into the microstructured fiber length.

Abstract: A method for making gradient refractive index optical components includes mixing a molten basic material (11) with a refractive index modifying material (21) in continuously changing proportions. The mixture is changed into a plurality of semi-molten fibers (41), and the fibers are rolled to form a continuous plate (51). The plate has a continuously changing refractive index along a lengthwise direction thereof. The plate is wound around a spindle (57) to obtain a wound preformed rod (58). The preformed rod is integrally fused by local heating, and drawn to form a draw (61) having a predetermined diameter. The draw is cut into pieces. Each piece can then be made into an optical component having a continuously changing refractive index in a radial direction. The method allows precise control of all steps, and such control is achieved with relative ease throughout.

Abstract: A method of manufacturing a two-dimensional (planar) optical waveguide comprises a first step of preparing a member having a thermoplastic structure (102) formed on a substrate (100), a second step of deforming the structure by heat treatment and a third step of forming an optical waveguide section (112) on the structure and the substrate.

Abstract: The present invention provides a method of efficiently manufacturing a dielectric waveguide with high reliability and precision. In the method, a resist material is formed on the outer surface of a green compact provided with a removal inhibiting layer, and predetermined portion of the green compact defined by the resist material is removed by the sand blasting method using the resist material as a mask, until the removal inhibiting layer is exposed to obtain a shaped green compact structure. The thus-obtained structure is fired to obtain a sintered body which comprises a dielectric strip and a wing.

Abstract: The present invention provides a method for forming a transparent optical element, such as an optical fiber, having a graded index of refraction. One preferred practice of the invention employs a hollow tube formed of an amorphous fluoropolymer and fills the tube with a liquid dopant material having an index of refraction that is different than that of the fluoropolymer. The heating of the filled tube for a sufficient duration causes the diffusion of the dopant material through the fluoropolymer, thereby producing a graded distribution of the dopant and hence a graded refractive index.

Abstract: After an optical waveguide substrate including a supporting substrate is adhered to an electric wiring board, the supporting substrate alone is dissolved using an organic solvent for removal. Alternatively, the supporting substrate alone is melted through a thermal treatment for removal. Further, a core layer of an optical waveguide is formed on the substrate using a photosensitive resin having a thermal expansion coefficient substantially identical to that of the supporting substrate.

Abstract: A method of manufacturing a medical instrument for diffusing light from an optical fiber is provided. The medical instrument includes an optical fiber having a proximal portion including a cladding layer surrounding the core and a distal portion having a diffuser tip comprising a protective coating made of acrylic or methylpentene surrounding the core, an optical coupling layer, and a sleeve. The protective coating strengthens the distal end of the optical fiber so that it can withstand a higher bending moment at failure than the uncladded core. At the same time, the protective layer has an index of refraction that is between the indices of refraction of the core and the optical coupling layer to direct light out of the core through to the optical coupling layer.

Abstract: A method of cooling an optical fiber while it is being drawn through contact with at least one cooling fluid in at least one cooling area, wherein said method is such that fast cooling, i.e. cooling that is faster than cooling in the surrounding air, is followed by slow cooling, i.e. cooling slower than cooling in the surrounding air, the temperature of the fiber in an intermediate area between the two cooling areas lying in the range 1200° C. to 1700° C. in the case of silica glass fibers.

Abstract: A method of cooling an optical fiber during drawing through contact with at least one cooling fluid in at least one cooling area, wherein fast cooling, i.e. cooling that is faster than cooling in the surrounding air, from an initial temperature of the fiber to a temperature at the end of fast cooling of said fiber, is followed by slow cooling, i.e. cooling slower than cooling in the surrounding air, from a temperature of said fiber at the start of slow cooling to a temperature of said fiber at the end of slow cooling.

Abstract: A starting material for producing optical fibers contains metal halides. The refractive index of the optical fiber formed from the starting marterial is predeterminable by adjusting a composite of the molten bath. The starting material is produced by mixing halogenated gases into a gas mixture with the desired partial pressure ratio, causing a chemical reaction at a first temperature of the gas mixture with at least metal to form a reaction product, the first temperature being higher than the melting temperature of the reaction product and cooling the reaction product to a second temperature that is below the melting temperature.

Abstract: A method of preparing an object with a radially-varying property is disclosed which includes the steps of providing a preform reactor including an outer container having a bottom, an inner container installed in the outer container, the inner container having a bottom, a rotating rod installed at a position in the outer container, and a sealing member for sealing the outer and inner containers at the bottoms thereof; filling the inner container with an inner material and a space between the inner container and the outer container with an outer material wherein the outer material has a different property from the inner material; removing the inner container; and rotating the rotating rod for laminar mixing of the inner and outer materials. An apparatus for carrying out the inventive method, and objects formed in accordance with the inventive method, are also disclosed.

Abstract: Optical fiber is provided with a periodically reversing spin while the fiber is pulled through a melt zone. A cooled region of the fiber downstream from the melt zone passes between a pair of opposed elements. The opposed elements are moved so that surface regions engaging the fiber move in opposite lateral directions relative to one another, thus spinning the fiber about its axis. The lateral movement of the engaged surface portions is periodically reversed to reverse the spin direction. The opposed elements may include belts or rollers, which can be tilted to orientations oblique to the longitudinal direction of the fiber.

Abstract: A method for making gradient refractive index optical components includes mixing a molten basic material (11) with a refractive index modifying material (21) in continuously changing proportions. The mixture is changed into a plurality of semi-molten fibers (41), and the fibers are rolled to form a continuous plate (51). The plate has a continuously changing refractive index along a lengthwise direction thereof. The plate is wound around a spindle (57) to obtain a wound preformed rod (58). The preformed rod is integrally fused by local heating, and drawn to form a draw (61) having a predetermined diameter. The draw is cut into pieces. Each piece can then be made into an optical component having a continuously changing refractive index in a radial direction. The method allows precise control of all steps, and such control is achieved with relative ease throughout.

Abstract: In a method of manufacturing an optical medium, an extended optical conductor containing active substance is formed to a predetermined shape by the use of resin by repeatedly folding or winding the optical conductor. A laser light beam or an amplified light beam is outputted from an edge portion of the optical conductor by absorbing an excitation light beam incident from the side surface of the optical conductor into the active substance through the resin. Thermoplastic resin is used as the resin. The thermoplastic resin transmits the excitation light beam. The resin is heated up to a glass transition temperature or higher. The optical conductor and the resin are bonded to each other so as to constitute a predetermined shape. The resin is cured.

Abstract: Light fibers comprising: (a) an elongate polymeric core having an input end for receiving light from a light source, an output end for emitting light transmitted through the core, and a lateral surface extending along a longitudinal axis of the core between the input end and the output end; (b) a light-emitting region directing light traveling though the light fiber out of at least a portion the lateral surface of the light fiber in a direction generally transverse to the longitudinal axis, the light-emitting region comprising at least one optical element; and (c) a continuous outer cladding layer comprising a polymeric material having a lower index of refraction than the core extending over the lateral surface of the core and the optical elements. Methods of making the light fibers using an embossing process are also reported.

Abstract: A novel optical fiber, and a method for its production, having a diffuser portion and continuous unitarily-constructed outer sleeve, which is adapted for the transmission of light to a treatment locale. More particularly, a medical instrument has an optical fiber including a diffuser portion at a distal end wherein an alignment sleeve for the optical fiber extends uninterruptedly in a single piece from a connector for a laser light source to at least the distal end of the core of the optical fiber.

Abstract: A cavity-preventing type reactor and a method for fabricating a preform for a plastic optical fiber using the same, wherein post-process charging of additional monomer or prepolymer into rotationally-induced central cavities is avoided by forming void-free plastic fibers using special geometric flow controllers combined with special materials combinations, pressures, and rotational techniques.

Abstract: Elastomeric stamps facilitate direct patterning of electrical, biological, chemical, and mechanical materials. A thin film of material is deposited on a substrate. The deposited material, either originally present as a liquid or subsequently liquefied, is patterned by embossing at low pressure using an elastomeric stamp having a raised pattern. The patterned liquid is then cured to form a functional layer. The deposition, embossing, and curing steps may be repeated numerous times with the same or different liquids, and in two or three dimensions. The various deposited layers may, for example, have varying electrical characteristics, interacting so as to produce an integrated electronic component.

Abstract: A production method of a light guide and a stamper, combining anisotropic etching and isotropic etching. First a plurality of microstructures is formed on a back surface and a front surface of the substrate. By electroforming, rear and front stampers are made from the back and front surfaces of the substrate. Light guides are produced using the rear and front stampers. Anisotropic etching is performed on the front surface of the substrate, forming V-shaped, U-shaped or pyramid like microstructures. Isotropic etching is performed on the back surface of the substrate, forming quadratic, bowl like, oval or semicircular microstructures. If a transparent substrate is used, then after finishing the etching of microstructures, a light source, a reflector, a diffusion sheet and a prism sheet are added, simulating a back light module for performing a test of luminosity, uniformity of light intensity and light emission angle, so that optical properties are known before proceeding with inverse-forming of the stampers.

Abstract: A planar optical device is formed on a substrate. The device comprises an array of waveguide cores which guide optical radiation. A cladding layer is formed contiguously with the array of waveguide cores to confine the optical radiation to the array of waveguide cores. At least one of the array of waveguide cores and cladding layer is an inorganic-organic hybrid material that comprises an extended matrix containing silicon and oxygen atoms with at least a fraction of the silicon atoms being directly bonded to substituted or unsubstituted hydrocarbon moieties. This material can be designed with an index of refraction between 1.4 and 1.55 and can be deposited rapidly to thicknesses of up to 40 microns. In accordance with another embodiment of the invention, a method for forming a planar optical device obviates the need for a lithographic process.

Abstract: A method in which a separate preformed optical material is suitably sized for easy handling, manipulation, and fabrication into a waveguide having a core (formed from the optical material) having transverse cross-sectional dimensions on the order of only tens of microns. The method may include a plurality of mechanical steps, e.g., lapping, polishing, and/or dicing, and bonding steps, e.g., attaching with adhesives. In one embodiment, the method includes the steps of providing an optical material, thinning and polishing the optical material to form a core comprising a plurality of longitudinally extending surfaces, providing a plurality of support substrates, and attaching the plurality of support substrates to the longitudinally extending surfaces of the core. The plurality of support substrates may be attached to the plurality of longitudinally extending surfaces of the optical material with an adhesive.

Abstract: A polymer optical waveguide includes a lower cladding layer of a polymer resin which has a recess and projection transferred from a mold provided with a recess and projection for forming a core portion of the optical waveguide by applying a polymer in molten state or in solution on the mold, and curing the polymer by ultraviolet rays or by heat, and stripping the cured polymer from the mold in a liquid. The cured polymer can be easily stripped from the mold, which allows the mass manufacturing of polymer optical waveguides having various film thicknesses.

Abstract: A method of fabricating an elongate light guide includes providing a moving mold assembly with at least two mold parts, wherein the mold parts have an engaged portion and a non-engaged portion. The mold parts are moved such that the non-engaged portions move in a first direction and the engaged portions move in a second direction different from the first direction to form an elongate regenerated mold cavity having a longitudinal axis, wherein the cavity comprises a molding surface with at least one structure transverse to the longitudinal axis. A thermosettable material is introduced into the cavity and at least partially polymerized in the cavity to form a light guide therein. The light guide is then removed from the mold assembly.

Abstract: A process for producing an optical fiber cable composite structural component, such as reinforcing members, buffer tubes, filler rods, jackets, and slotted cores, is disclosed. The composite structural components are produced by co-extruding a thermotropic liquid crystalline polymer (TLCP) and a thermoplastic matrix material into the composite structural component so that TLCP reinforcing fibrils are dispersed in the thermoplastic matrix material. The TLCP reinforcing fibrils undergo a high level of process induced orientation, are provided with a high aspect ratio, and small diameters. The composite structural component has a high modulus. The TLCP reinforcing fibrils may be made continuous or discontinuous.

Abstract: An extruder heats polymer resin to produce molten polymer and supplies the molten polymer at a constant pressure. A gear pump is in fluid communication with the extruder, receives the molten polymer and controls the polymer flow rate. A spinneret is in fluid communication with the gear pump and spins the molten polymer into the optical fibers. A heater controls the temperature of the optical fibers after the fibers exit the spinneret. The optical fibers are slowly cooled from molten to ambient temperature to eliminate radial morphological variations. A take-up roller tensions the optical fibers after the fibers exit the spinneret to maximize crystallization of the molten polymer.