Method of co-drawing hybrid incompatible materials

Abstract

A method of drawing different materials includes forming a first material into a preform body defining at least one channel extending therethrough having a first cross-sectional area. A first element formed of a second material is inserted into the channel and with the preform body creates a preform assembly. The first element has a cross-sectional area that is less than the cross-sectional area of the channel, and the second material has a higher melting temperature than the first material. The preform assembly is heated so that the first material softens and the preform assembly is drawn so that the preform body deforms at a first deformation rate to a smaller cross-sectional area and the first element substantially maintains a constant cross-sectional area throughout the drawing process. Upon completion of the drawing step, the cross-sectional area of the channel is equivalent to the cross-sectional area of the first element.

1 . A method of co-drawing different materials, comprising the steps of:
 providing a preform body comprising one or more first materials, the preform body defining at least one channel extending therethrough, the channel having a first cross-sectional area; wherein an element formed of one or more second materials is inserted into and through the channel in the preform body and in combination with the preform body, creating a preform assembly; wherein the element has a cross-sectional area that is less than the cross-sectional area of the at least one channel, and further wherein the one or more second materials do not melt at melting temperatures for the first one or more materials;   heating the preform assembly to a point where the one or more first materials soften; and drawing the preform assembly in such a manner that the preform body deforms to define   a smaller cross-sectional area of said at least one channel and the cross sectional area of the element does not change as much as the cross sectional area of the one or more first materials does throughout the drawing process.   
     
     
         2 . The method of  claim 1 , wherein the drawing step further comprises continuously feeding the element as the preform body continues to be drawn. 
     
     
         3 . The method of  claim 1 , wherein the preform body is approximately cylindrical. 
     
     
         4 . The method of  claim 1 , wherein the preform body is approximately rectangular. 
     
     
         5 . A method of co-drawing different materials, comprising the steps of:
 providing an approximately rectilinear preform body comprising at least one or more first materials, the preform body defining at least one channel extending therethrough, the at least one channel having a polygon-shaped cross-sectional area with concave sections extending towards the center of the channel forming at least two rails from the one or more first materials protruding from first opposite walls of the at least one polygon-shaped channel; wherein a first element comprising one or more second materials and a second element comprising one or more third materials are inserted into and through the at least one channel in the preform body forming a preform assembly , wherein the first and second elements are abutted to second opposite walls in the channel and wherein the first and second elements each have a cross-sectional area that is less than the cross-sectional area of the at least one channel, and further wherein the one or more second materials and the one or more third materials do not melt at melting temperatures for the one or more first materials;   heating the preform assembly to a point where the one or more first materials soften;   drawing the preform assembly in such a manner that the rails linearly converge toward the center of the at least one channel to at least partially engage the first and second elements while maintaining said first and second elements opposite to each other; wherein cross sectional areas of said first and second elements do not change as much as the cross sectional area of the one or more first materials do throughout the drawing process;   wherein, upon completion of the drawing step, the cross-sectional area of the preform body is reduced so that it closely engages said first and second elements and defines a reduced channel between said first and second elements.   
     
     
         6 . The method of  claim 5 , wherein the at least one channel is filled with a gas. 
     
     
         7 . The method of  claim 1 , wherein, upon completion of the drawing step, the cross-sectional area of the channel is equivalent to the cross-sectional area of the element. 
     
     
         8 . The method of  claim 5 , wherein the polygon-shaped at least one channel is shaped as a concave dodecagon. 
     
     
         9 . A method of co-drawing different materials, comprising the steps of:
 providing a preform body comprising one or more first materials, the preform body defining first and second arcuate channels arranged with respect to an outer surface of the preform body; wherein a first element comprising one or more second materials is inserted into and through the first channel and a second element comprising one or more third materials is inserted into and through the second channel in the preform body, forming a preform assembly; wherein the first and second elements each have a cross-sectional area that is less than the cross-sectional areas of the first and second channels, and further wherein the one or more second materials and the one or more third materials do not melt at melting temperatures for the one or more first materials;   heating the preform assembly to a point where the one or more first materials soften;   drawing the preform assembly in such a manner that the first channel converges toward the first element so that the first element engages and assumes the shape of the first channel, and such that the second channel converges towards the second element so that the second element engages and assumes the shape of the second channel, wherein the first and second elements are not substantially deformed longitudinally;   wherein, upon completion of the drawing step, the cross-sectional area of the preform body is reduced so that it closely engages said first and second elements and so that it flexes the first and second elements into arcuate cross-sectional forms.   
     
     
         10 . The method of  claim 9 , wherein the channels are filled gas. 
     
     
         11 . The method of  claim 9 , wherein the preform body is approximately cylindrical and the first and second arcuate channels are concentrically arranged with respect to said outer surface of the preform body. 
     
     
         12 . The method of  claim 9 , wherein the one or more second materials and the one or more third materials are flexible. 
     
     
         13 . The method of  claim 1 , wherein the one or more first materials and/or the one or more second materials comprise a metal. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . A LED device manufactured by the process of  claim 1 . 
     
     
         18 . A photovoltaic cell device manufactured by the process of  claim 1 . 
     
     
         19 . A device with electrically, magnetically or thermally induced change in its optical, electrical, physical or chemical properties manufactured by the process of  claim 1 . 
     
     
         20 . A nonlinear optical device manufactured by the process of  claim 1 . 
     
     
         21 . The method of  claim 1 , wherein the drawing step further comprises continuously feeding the element as the preform body continues to be drawn, interrupting the continuous feeding of the element, and initiating a step of continuously feeding a second element comprising one or more third materials. 
     
     
         22 . The method of  claim 1 , further comprising heating the preform assembly such that the one or more first materials soften to a first viscosity; the one or more second materials soften to a second viscosity; and the cross-section of the preform body and the cross section of the element shrink at different ratios.