U.S. patent application number 11/888182 was filed with the patent office on 2009-02-05 for fiber optic cables having coupling and methods therefor.
Invention is credited to William Eric Caldwell, Kenneth D. Temple, JR., Richard S. Wagman.
Application Number | 20090034918 11/888182 |
Document ID | / |
Family ID | 40338227 |
Filed Date | 2009-02-05 |
United States Patent
Application |
20090034918 |
Kind Code |
A1 |
Caldwell; William Eric ; et
al. |
February 5, 2009 |
Fiber optic cables having coupling and methods therefor
Abstract
A fiber optic cable including at least one optical fiber
disposed within a cavity of a cable jacket and methods for
manufacturing the same are disclosed. The cavity has a first cavity
cross-sectional area and a second cavity cross-sectional area
located at different longitudinal locations along the cable, where
the first cavity cross-sectional area is greater than the second
cavity cross-sectional area. The region of the second cavity
cross-sectional area of the cable provides and/or increases the
coupling level of the at least one optical fiber to the cable
jacket. In further embodiments, the fiber optic cable is a dry
cable having one or more dry insert within the cavity for
cushioning and/or optionally providing water-blocking for the
cable.
Inventors: |
Caldwell; William Eric;
(Taylorsville, NC) ; Wagman; Richard S.; (Hickory,
NC) ; Temple, JR.; Kenneth D.; (Newton, NC) |
Correspondence
Address: |
CORNING INCORPORATED
INTELLECTUAL PROPERTY DEPARTMENT, SP-TI-3-1
CORNING
NY
14831
US
|
Family ID: |
40338227 |
Appl. No.: |
11/888182 |
Filed: |
July 31, 2007 |
Current U.S.
Class: |
385/107 ;
385/102 |
Current CPC
Class: |
G02B 6/4494 20130101;
G02B 6/4433 20130101; G02B 6/4486 20130101; G02B 6/4403
20130101 |
Class at
Publication: |
385/107 ;
385/102 |
International
Class: |
G02B 6/44 20060101
G02B006/44 |
Claims
1. A fiber optic cable comprising; at least one optical fiber; and
a cable jacket, the cable jacket having at least one cavity,
wherein the at least one optical fiber is disposed within the at
least one cavity, the at least one cavity having a first cavity
cross-sectional area (CA1) and a second cavity crops-sectional area
(CA2) located at different longitudinal locations along the cable,
wherein the first cavity cross-sectional area is greater than the
second cavity cross-sectional area.
2. The fiber optic cable of claim 1, the cavity having a cavity
cross-sectional ratio being defined as the second cavity
cross-sectional area divided by the first cavity cross-sectional
area, wherein the cavity cross-sectional ratio (CA2/CA1) is between
about 50 % and about 90 %.
3. The fiber optic cable of claim 1, the at least one optical fiber
having a predetermined level of coupling to the cable jacket
wherein the predetermined level of coupling is about 0.1625 Newtons
or more per optical fiber for a thirty meter length of fiber optic
cable.
4. The fiber optic cable of claim 1, further comprising one or more
water blocking elements disposed in the at least one cavity
selected from the group of a water blocking powder, a water
blocking yarn, a water-blocking thread, a water blocking tape, and
a water blocking gel.
5. The fiber optic cable of claim 1, further comprising one or more
dry inserts disposed in the at least one cavity.
6. (canceled)
7. The fiber optic cable of claim 1, further comprising further
comprising a first strength element and a second strength element
attached to the cable jacket on opposite sides of the at least one
cavity.
8. (canceled)
9. The fiber optic cable of claim 1, the fiber optic cable having a
flame-retardant characteristic.
10. (canceled)
11. The fiber optic cable of claim 1, wherein the fiber optic cable
is a portion of a fiber optic cable assembly.
12. A fiber optic cable comprising: at least one optical fiber; at
least one dry inserts; and a cable jacket, the cable jacket having
at least one cavity, wherein the at least one optical fiber and the
at least one dry insert are disposed within the at least one
cavity, the cavity having a first cavity cross-sectional area (CA1)
and a second cavity cross-sectional area (CA2) located at different
longitudinal locations along the cable, wherein the first cavity
cross-sectional area is greater than the second cavity
cross-sectional area.
13. The fiber optic cable of claim 12, the cavity having a cavity
cross-sectional ratio being defined as the second cavity
cross-sectional area divided by the first cavity cross-sectional
area, wherein the cavity cross-sectional ratio (CA2/CA1) is between
about 50 % and about 90 %.
14. The fiber optic cable of claim 12, the at least one optical
fiber having a predetermined level of coupling to the cable jacket
wherein the predetermined level of coupling is about 0.1625 Newtons
or more per optical fiber for a thirty meter length of fiber optic
cable.
15. The fiber optic cable of claim 12, further comprising one or
more water blocking elements disposed in the at least one cavity
selected from the group of a water blocking powder, a
water-blocking yarn, a water blocking thread, a water blocking
tape, and a water blocking gel.
16. The fiber optic cable of claim 12, the at least one dry insert
having a compressible layer and a water-swellable layer that are
attached together.
17. (canceled)
18. The fiber optic cable of claim 12, further comprising a first
strength element and a second strength element attached to the
cable jacket on opposite sides of the at least one cavity.
19. (canceled)
20. The fiber optic cable of claim 12, the fiber optic cable having
a flame-retardant characteristic.
21. (canceled)
22. The fiber optic cable of claim 12, wherein the fiber optic
cable is a portion of a fiber optic cable assembly.
23. A method for manufacturing a fiber optic cable comprising at
least one optical fiber disposed in at least one cavity of a cable
jacket comprising the steps of: providing at least one optical
fiber; applying a cable jacket about the at least one optical
fiber, the cable jacket having a cavity, wherein the step of
applying the cable jacket includes changing a cavity
cross-sectional area between a first location and a second location
along a length of the cable jacket for improving coupling of the at
least one optical fiber.
24. The method of claim 23, the step of changing of the cavity
cross-sectional area being selected from the group of applying a
cable jacket having a wall thickness that varies the cavity
cross-sectional area at one or more locations along the cable
jacket or deforming the cable jacket while is it still molten.
25. The method of claim 23, wherein the at least one cavity has a
first cavity cross-sectional area (CA1) and a second cavity
cross-sectional area (CA2) located at different longitudinal
locations along the cable and a cavity cross-sectional ratio is
defined as the second cavity cross-sectional area divided by the
first cavity cross-sectional area, wherein the cavity
cross-sectional ratio (CA2/CA1) is between about 50 % and about 90
%.
26. The method of claim 23, wherein the at least one optical fiber
has a predetermined level of coupling to the cable jacket wherein
the predetermined level of coupling is about 0.1625 Newtons or more
per optical fiber for a thirty meter length of fiber optic
cable.
27. The method of claim 23 further comprising the step of providing
one or more water blocking elements for inhibiting the migration of
water along the fiber optic cable.
28. The method of claim 23, further comprising the step of applying
one or more dry inserts that are disposed within the at least one
cavity.
29. (canceled)
30. The method of claim 23, further comprising the step of applying
a first strength element and a second strength element, wherein the
first strength element and the second strength element are disposed
on opposite sides of the at least one cavity.
31. (canceled)
32. The method of claim 23, the step of applying the cable jacket
including using a polymer having a flame-retardant
characteristic.
33. The method of claim 23, further comprising the step of applying
an armor component.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to fiber optic
cables and assemblies that are useful for routing optical fibers
toward the subscriber and/or other suitable cables/assemblies in an
optical network. Specifically, the fiber optic cables and
assemblies of the present invention have one or more features for
providing and/or tailoring the level of coupling for the optical
fibers, optical fiber ribbons, or the like.
BACKGROUND OF THE INVENTION
[0002] Communication networks are used to transport a variety of
signals such as voice, video, data transmission, and the like.
Traditional communication networks use copper wires in cables for
transporting information and data. However, copper cables have
drawbacks because they are large, heavy, and can only transmit a
relatively limited amount of data with a reasonable cable diameter.
Consequently, optical waveguide cables replaced most of the copper
cables in long-haul communication network links, thereby providing
greater bandwidth capacity for long-haul links. However, most
communication networks still use copper cables for distribution
and/or drop links on the subscriber side of the central office. In
other words, subscribers have a limited amount of available
bandwidth due to the constraints of copper cables in the
communication network. Stated another way, the copper cables are a
bottleneck that inhibit the subscriber from utilizing the
relatively high-bandwidth capacity of the optical fiber long-haul
links.
[0003] Fiber optic cables used for distribution or drop links
should have the necessary characteristics for the application. For
instance, the fiber optic cable designs should provide
water-blocking, cushion the optical fibers, couple the optical
fibers to the buffer tube or cable jacket, and allow movement of
the optical fibers during bending, installation, or the like
However, not all fiber optic cable designs provided all of these
characteristics and instead rely on installation procedures to
achieve the desired characteristics.
[0004] For instance, some fiber optic cable designs can require
special installation procedures such as coiling the cable at
specified intervals for providing coupling to the optical fibers.
Using installation procedures to achieve the desired
characteristics can be problematic and/or add complexity and
expense. By way of example, the fiber optic cable can be installed
improperly and fail to provide the proper level of coupling.
Additionally, the coiling of the cable requires extra cable length
within the optical network. If the fiber optic cable is used as a
distribution cable, coiling of the cable can interfere with
intended node locations (e.g., distribution locations) along the
length of the cable.
[0005] Thus, there has been a long-felt need for fiber optic cable
designs that provide all of the required performance
characteristics along with quick and easy access and deployment
without requiring special installation techniques. Moreover, the
reliability and robustness of the fiber optic cables and the
interconnection therebetween must withstand the rigors of an
outdoor environment.
SUMMARY OF THE INVENTION
[0006] To achieve these and other advantages and in accordance with
the purpose of the invention as embodied and broadly described
herein, the invention is directed to fiber optic cables that have
one or more features for providing and/or tailoring the level of
coupling for the optical fibers, optical fiber ribbons, or the like
and methods for making the same.
[0007] One aspect the invention is directed to a fiber optic cable
having at least one optical fiber disposed within a cavity of a
cable jacket that changes cross-sectional area along its
longitudinal length for providing and/or tailoring coupling.
Specifically, the cavity has a first cavity cross-sectional area
and a second cavity cross-sectional area located at different
longitudinal locations along the cable, wherein the first cavity
cross-sectional area is greater than the second cavity
cross-sectional area. By way of example, the cavity has a cavity
cross-sectional ratio defined as the second cavity cross-sectional
area divided by the first cavity cross-sectional area, where the
cavity cross-sectional ratio is between about 50% and about 90%. In
advantageous embodiments, the fiber optic cables are dry cable
designs that eliminate the thixotropic grease/gel from the cable.
Additionally, the present invention is directed to methods for
making fiber optic cables where the cross-sectional area of the
cavity changes along it longitudinal length.
[0008] Another aspect the invention is directed to a fiber optic
cable having at least one optical fiber and a dry insert disposed
within a cavity of a cable jacket where the dry insert changes
thickness along its longitudinal length for providing and/or
tailoring coupling. Specifically, the dry insert has a first
thickness at a first longitudinal location and a second thickness
at a second longitudinal location where the first thickness is
greater for the second thickness, thereby creating a thickness
variation along the longitudinal length of the at least one dry
insert. By way of example, the dry insert has a dry insert
thickness ratio defined as the second thickness divided by the
first thickness, where the dry insert thickness ratio is between
about 50% and about 90%. Additionally, the present invention is
directed to methods for making fiber optic cables where the dry
insert changes thickness along it longitudinal length.
[0009] It is to be understood that both the foregoing general
description and the following detailed description present
exemplary and explanatory embodiments of the invention, and are
intended to provide an overview or framework for understanding the
nature and character of the invention as it is claimed. The
accompanying drawings are included to provide a further
understanding of the invention, and are incorporated into and
constitute a part of this specification. The drawings illustrate
various exemplary embodiments of the invention, and together with
the description, serve to explain the principles and operations of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a plan view showing the location of
cross-sectional planes of an explanatory fiber optic cable
according to the present invention.
[0011] FIGS. 2A and 2B depict respective cross-sectional views at
the cross-sectional planes of FIG. 1 for an explanatory dry fiber
optic cable.
[0012] FIGS. 3A-3D depict respective cross-sectional views of
explanatory dry inserts for use with the concepts of the present
invention.
[0013] FIGS. 4A and 4B depict respective cross-sectional views at
the sectional planes of FIG. 1 for another explanatory dry fiber
optic cable according to the present invention.
[0014] FIGS. 5A and 5B depict respective cross-sectional views at
the sectional planes of FIG. 1 for still another explanatory dry
fiber optic cable according to the present invention.
[0015] FIGS. 6A and 6B depict respective cross-sectional views at
the sectional planes of FIG. 1 for a toneable fiber optic cable
according to the present invention.
[0016] FIGS. 7A and 7B depict respective cross-sectional views at
the sectional planes for a fiber optic cable having armor according
to the present invention.
[0017] FIGS. 8A and 8B depict respective cross-sectional views at
the sectional planes for a fiber optic cable having armor according
to the present invention.
[0018] FIGS. 9A and 9B depict respective cross-sectional views at
the sectional planes for a round fiber optic cable according to the
present invention.
[0019] FIG. 10 is a side view of a generic dry insert having a
change in thickness along a longitudinal direction according to the
concepts of the present invention.
[0020] FIGS. 11A and 11B are respective cross-sectional views
showing an explanatory fiber optic cable using the dry insert of
FIG. 10 according to the present invention.
[0021] FIG. 12 schematically depicts an explanatory manufacturing
line for making fiber optic cables according to the present
invention.
[0022] FIGS. 13A and 13B schematically depicts concepts for
changing a cross-sectional area of the cavity according to the
present invention.
[0023] FIGS. 14A and 14B schematically depict another method for
changing a cross-sectional area of the cavity according to the
present invention.
[0024] FIG. 15 depicts a perspective view of a fiber optic cable
assembly that includes a fiber optic cable along with a tether
cable that is preconnectorized with a hardened connector according
to the present invention.
[0025] FIG. 16 depicts another perspective view of a fiber optic
cable assembly that includes a fiber optic cable along with a
tether cable having a multiport according to the present
invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0026] Reference will now be made in detail to exemplary
embodiments of the invention, examples of which are described
herein and shown in the accompanying drawings. Whenever practical,
the same reference numerals are used throughout the drawings to
refer to the same or similar parts or features. FIG. 1 depicts an
explanatory fiber optic cable 10 (hereinafter cable 10) according
to the present invention that can be configured for use as a drop
cable, a distribution cable, or other suitable portions of an
optical network. Generally speaking, a distribution cable will have
a relatively high optical fiber count such twelve or more optical
fibers for further distribution to the optical network. On the
other hand, a drop cable will have a relatively low optical count
such as up to four optical fibers for routing towards a subscriber
or a business, but drop cables may include higher fiber counts. As
depicted, the portion of cable 10 shown includes an A-region
disposed between a first B-region and a second B-region along its
longitudinal length as noted by the brackets. Cables of the
invention have A-regions and B-regions that provide different
levels of coupling of the optical fiber to the cable jacket or
tube, thereby advantageously allowing tailoring of the coupling
level for the optical fiber(s). Specifically, the cable design
tailors the desired level of coupling by using a cross-sectional
restriction of a cavity for the cable jacket/tube and/or using a
cable component such as a dry insert with a thickened portion.
Moreover, the concepts of the invention may also be advantageous
since the B-region also provides a necked down area and/or cable
component filled area where inhibiting the migration of water along
the cable is easier. Explanatory cross-sectional views of the
different regions of explanatory cable 10 are taken at
cross-sectional planes A-A and B-B as shown by FIG. 1 and represent
the respective A-region and B-region for each cable.
[0027] FIGS. 2a and 2b depict respective cable cross-sections for
an explanatory dry cable 10 respectively taken along
cross-sectional planes A-A and B-B of FIG. 1. As shown, cable 10
includes at least one optical fiber (not visible) that is a portion
of an optical fiber ribbon 13 (represented by the horizontal line),
a first dry insert 22, a second dry insert 23, at least one
strength member 24, and a cable jacket 28 having a cavity 28a.
Generally speaking, cable 10 shown in FIGS. 2a and 2b has a
generally flat profile, but other cable designs can have other
profiles such as round or the like. In other words, cable jacket 28
has two major surfaces (not numbered) that are generally flat and
are connected by arcuate end surfaces (not numbered) as shown,
thereby resulting in a cable having a relatively small
cross-sectional footprint. Generally speaking, cavity 28a of cable
jacket 28 has a generally rectangular shape for carrying one or
more fiber optic ribbons in a non-stranded configuration. Simply
stated, optical fiber ribbon 13 is disposed between first dry
insert 22 and second dry insert that have a compressible layer,
thereby providing cushioning, coupling, and optionally
water-blocking. As shown, this cable also has strength members
24,24 disposed on opposing sides of cavity 20, thereby imparting a
preferential bend characteristic to the cable that is generally
aligned with the preferential bend characteristic of the ribbon. By
way of example, strength members 24,24 are preferably a dielectric
material such as glass-reinforced plastic (GRP) having a diameter
such as about 2.3 millimeters, thereby allowing an all dielectric
cable design; however, other strength member material, sizes,
and/or shapes are possible. For instance, strength members can use
a conductive material such as steel, copper-clad steel, or the like
and/or they may have shapes other than round such as the oval.
[0028] Cavity 28a is sized for allowing ribbons or optical fibers
the adequate freedom to move when, for instance, the cable is bent
while maintaining adequate optical attenuation performance and the
B-region has one or more features that allows the tailoring of the
coupling level of optical fibers to cable jacket 28. More
specifically, cavity 28a has a first cavity cross-sectional area
(CA1) depicted in FIG. 2A and a second cavity cross-sectional area
(CA2) depicted in FIG. 2B, where the first cavity cross-sectional
area (CA1) is greater than the second cavity cross-sectional area
(CA2). As shown, the change in cavity cross-sectional areas is
generally attributable to a change between a first cavity height
CH1 and a second cavity height CH2 since the cavity width (not
numbered) remains similar. As represented by FIG. 2B, second cavity
cross-sectional area (CA2) is asymmetrical about the neutral
bending axis of the cable, but other configurations could have
generally symmetrical second cavity cross-sectional area about the
neutral bending axis. The orientation of the second cavity
cross-sectional area may depend on the method for creating the
B-region as discussed herein. By way of example, cavity 28a can
have a cavity cross-sectional ratio defined as the second cavity
cross-sectional area (CA2) divided by the first cavity
cross-sectional area (CA1) with the cavity cross-sectional ratio
(CA2/CA1) being between about 50% and 90%. By way of a numerical
illustration, a nominal cavity height for the A-region is 5.5
millimeters and a nominal cavity height for the B-region is about
3.7 millimeters (with the same cavity width), thereby yielding a
cavity cross-sectional ratio of about 67%.
[0029] Simply stated, the B-region allows tailoring of the coupling
by providing and/or increasing the compression of the dry inserts
22,23 (i.e., the B-region may provide all of the coupling or a
substantial fraction thereof). Compression of dry insert(s) is
actually a localized maximum compression of the dry insert(s) that
occurs where the ribbons undulate into the same due to the excess
ribbon length (ERL) of the optical fiber ribbon 13 (i.e., the
ribbons are longer than the cavity for the length of the cable). In
other words, the compression of the dry inserts creates a normal
force on the ribbon(s), thereby helping maintain the longitudinal
position of the optical fibers/ribbons during normal cable
operating conditions. Further, cable 10 can have a plurality of
B-regions disposed along its longitudinal length with predetermined
spacing and/or lengths (i.e., intermittently disposed along the
length of the cable) for the B-region to tailor to a desired level
of coupling. For instance, the cable can have a plurality of
B-regions having a longitudinal length of between about 1-10
centimeters disposed between A-regions having a longitudinal length
of between about 300-10,000 centimeters, but other suitable region
lengths and/or patterns are possible. Using a relatively short
length for the B-region tends to force a node at that location for
the undulating optical fibers, while still allowing the optical
fibers the necessary freedom to move.
[0030] Optical fiber ribbons 13 used in the cables of the present
invention can have any suitable design or ribbon count as known in
the art or developed hereafter. For instance, optical fiber ribbons
13 can have any suitable subunit construction, a common matrix
construction, geometry, stress concentrators, different fiber
counts, and/or the like. Subunits allow predetermined splitting of
the optical fiber ribbons into predictable smaller fiber count
units, preferably without the use of special tools. By way of
example, fiber optic ribbon 13 is a twenty-four fiber ribbon having
two twelve-fiber units each having three subunits with four optical
fibers. Of course, other suitable twenty-four fiber ribbon
configurations are possible such as two twelve fiber units, three
eight fiber units, four six fiber units, or six four fiber units
depending on the requirements of the network architecture.
[0031] Optical fibers preferably have an excess fiber length (EFL)
compared with a length of cavity 28a; however, in some instances
the EFL may also be slightly negative. Likewise, ribbons can have
an excess ribbon length (ERL) with respect to the length of the
cavity. Besides inhibiting the application of strain to the optical
fibers, EFL or ERL can aid in coupling the optical fibers or
ribbons with the cable jacket or tube. By way of example, the ERL
is preferably in the range of about 0.1 percent to about 1.2
percent, and more preferably in the range of about 0.3 percent to
about 1.0 percent, and most preferably in the range of about 0.5
percent to about 0.8 percent, thereby inhibiting the application of
strain, allowing bending of the fiber optic cable without causing
elevated levels of optical attenuation, and/or suitable low
temperature performance. Additionally, the amount of ERL may depend
on specific cable design such as the number of ribbons within the
cavity, the cavity size, cavity shape, intended application, and/or
other parameters.
[0032] As depicted in FIG. 2B, coupling for optical fiber ribbon 13
is provided in the B-region by the compression of dry inserts 22,23
on optical fiber ribbon 13 due to the smaller cavity height CH2. No
matter the construction and/or materials of the dry insert(s) or
the like, the cable design should provide the desired level of
coupling for the optical fibers to the cable jacket or tube.
Additionally, in order to quantify the level of coupling for the
optical fibers a relatively long length of cable is required. By
way of example, optical fibers of cables according to the present
invention have a coupling force of at least about 0.1625 Newtons
per optical fiber for a thirty-meter length of fiber optic cable.
Illustratively, a fiber optic cable having a single ribbon with
twelve optical fibers in the ribbon should have a minimum coupling
force of about 1.95 Newtons for a thirty-meter length of fiber
optic cable. Likewise, a similar fiber optical cable having a
single optical fiber ribbon with six optical fibers should have a
minimum coupling force of about 0.975 Newtons for a thirty-meter
length of fiber optic cable. Measurement of the coupling force is
accomplished by taking a thirty-meter fiber optic cable sample and
pulling on a first end of the optical fibers (or fiber optic
ribbon(s)) and measuring the force required to cause movement of
the second end of the optical fiber(s) (or fiber optic ribbon(s)).
In other words, the EFL (or ERL) must be straightened so that the
coupling force is the amount of force required to move the entire
length of optical fibers within the thirty-meter fiber optic cable
sample.
[0033] Dry inserts can be any suitable material, materials and/or
structure such as one or more elongate tapes such as a foam tape
disposed within the cavity for coupling the ribbons with the cable
jacket or tube. Optionally, dry inserts can also include a
water-blocking characteristic for blocking the migration of water
along the cable. As depicted in FIGS. 2A and 2B, dry inserts 22,23
are disposed on both the top and bottom of ribbon 13. In other
words, the components form a elongate tape/ribbon sandwich with the
first elongate tape disposed on a first planar side of the ribbon
(or ribbon stack) and the second elongate tape being disposed on a
the second major side of the ribbon (or ribbon stack) within the
generally rectangular cavity. Stated another way, planar surface(s)
of the ribbon generally faces the planar surface of the dry inserts
and the planar surface of the same is also generally aligned with
the major dimension of the cavity so that all of the major planar
surfaces of the components are generally aligned within the
generally rectangular cavity as depicted. Of course, other
embodiments may have one or more dry inserts wrapped about the
optical fibers or disposed on one or more sides thereof. In this
cable, dry inserts 22,23 of FIG. 2A are elongate tapes formed from
an open cell foam such as a polyurethane material; however, other
suitable foam materials for coupling and cushioning of the ribbons
are possible such as polyethylene, polypropylene, EVA.
[0034] Additionally, one or more dry inserts can include an
optional water-swellable layer (represented by the solid hatching
of the dry insert and not numbered) for inhibiting the migration of
water within the cable. For instance, a foam layer and a
water-swellable layer are laminated together, thereby forming a
composite elongate tape (i.e., a water-swellable foam tape). In
other embodiments, the compressible layer and the optional
water-swellable layer are discrete individual components that are
unattached (i.e., a separate compressible layer and water-swellable
component such as being a water-swellable yarn or thread).
Generally speaking, dry inserts used herein are multi-functional.
For instance, besides aiding the coupling the optical fibers,
ribbons, modules, or the like to the cable jacket, they may
optionally inhibit the migration of water, as well as cushion the
optical fibers during bending of the cable. Although the dry
inserts are shown having a width smaller than the cavity, the dry
inserts may have a width that is greater than the cavity.
Additionally, dry inserts can have other constructions besides an
elongate foam tape and the optional water-swellable layer can have
any suitable material(s)/construction(s).
[0035] Illustratively, FIG. 3a depicts one example of another dry
insert 22'. Dry insert 22' includes a compressible layer formed
from a plurality of microspheres 22b' disposed between a top tape
22a' and bottom tape 22a'. As with other tapes used for the dry
insert, tapes 22a' can be formed from any suitable material such as
a non-woven material, a polyester film like Mylar, or other like
materials. More specifically, microspheres 22b' are generally
disposed between tapes 22a' and are attached using a suitable
method such as an adhesive, binding agent, application of heat
and/or pressure, or the like. Additionally, an optional
water-swellable substance such as a plurality of water-swellable
particles, a plurality of water-swellable fiber, or a
water-swellable coating 22c' may also be disposed between tapes
22a' with microspheres 22b' or on a portion one or more tapes 22a'.
Suitable materials for microspheres 22b' are relatively soft so
they are compressible and sized so that they will not cause undue
levels of optical attenuation if they press against the optical
fiber or ribbon. By way of example, suitable hollow microspheres
are available from Akzo Nobel of the Netherlands under the
tradename EXPANCEL and includes copolymers of monomers vinylidene
chloride, acrylonitrile, and methylmethacrylate. Other plastic
hollow microspheres are available from Asia Pacific Microspheres of
Malaysia under the tradename of PHENOSET, which are phenolic and
amino-based microspheres.
[0036] The compressible nature of hollow polymeric microspheres is
suited for providing adequate coupling of the optical fibers to the
tube or cable jacket. Additionally, the smooth round surface of
these microspheres permits pressing against the optical fibers
without inducing elevated levels of optical attenuation such as
during bending, twisting, or crushing of the cable. Additionally,
the size of the hollow microspheres can vary from about 1 micron to
about 300 microns, likewise, a wall thickness of the microspheres
can also vary from about 0.1 micron up to several microns, but
other suitable dimensions are possible as long as a suitable level
of optical performance is maintained.
[0037] FIG. 3b depicts another example of a dry insert 22'' that
provides a compressible layer 22b'' using the geometry of its
shape. More specifically, compressible layer 22b'' is provided by
using a dimensional fabric that has a generally textured shape in
one or more directions for providing the compressible layer. As
shown, dry insert 22'' has a generally textured shape TS and is
formed from a suitably soft and flexible material so that it can
deform for providing an adequate level of coupling for the optical
fibers or ribbons without causing undue levels of optical
attenuation. By way of example, suitable fabrics are available from
Freudenberg of Durham, N.C. under the name of Novolon. The
dimensional fabrics may be formed from a variety of materials such
as polyester, polypropylene, nylon, or other suitable materials.
Generally speaking, dimensional fabrics are formed using a molding
process for transforming a two-dimensional (i.e., flat) fabric or
substrate into a three-dimensional (i.e., textured shape) fabric or
substrate with the desired textured shape TS. The coupling and/or
compressibility of dry insert 22'' can be tailored by changing
parameters such as the number of contact points per surface area
(i.e., changing the density of high and low contact points), the
height from a high point to a low point, the dimension fabric
profile, and/or flexibility of the dimensional fabric. Again, dry
insert 22'' can include an optional water-swellable layer for
blocking the migration of water along the cable or tube assembly.
For instance, the water-swellable layer may be a coating applied to
one or more surfaces or applied to the fibers of the dimensional
fabric, include water-swellable particles disposed in or on the dry
insert, and/or may include superabsorbent fibers. Suitable
water-swellable filaments are, for example, LANSEAL materials
available from Toyobo of Osaka, Japan or OASIS materials available
from Technical Absorbents Ltd. of South Humberside, United
Kingdom.
[0038] FIG. 3c depicts a further embodiment of a dry insert 22'''
having a compressible layer 22b''' having a non-woven layer of felt
substance made of one or more materials formed from non-continuous
and/or continuous filaments. Dry insert 22''' may optionally
include a water-swellable layer and/or one or more tapes for
attaching the felt substance thereto. For instance, dry insert
22''' includes a plurality of water-swellable filaments 22a'''
along with other filaments 22b''' that are non-swellable disposed
between a plurality of optional tapes 22c''', thereby forming dry
insert 22''', As used herein, "felt substance" means a material
comprising one or more types of non-continuous or continuous
filaments and/or fibers which have been caused to adhere and/or
matt together through the action of heat, moisture, chemicals,
pressure, or mechanical action such as needle-punching or
spun-lacing, or a combination of the foregoing actions, thereby
forming a relatively thick and compressible layer. Water-swellable
filaments 22a''' may comprise any suitable water-swellable
material. By way of example, dry insert 22''' of FIG. 3c may
include about 25% or less by weight of water-swellable filaments
22a''' and about 75% or more by weight of other filaments 22b''';
however, other suitable ratios are possible. Other filaments 22b'''
may include any suitable filament and/or fiber material such as
polymer filaments like polypropylene, polyethylene, and polyesters,
likewise, other suitable materials such as cottons, nylon, rayons,
elastomers, fiberglass, aramids, polymers, rubber-based urethanes,
composite materials and/or blends thereof may be included as a
portion of other filaments 22b''' and may be tailored for providing
specific characteristics.
[0039] FIG. 3d depicts yet another dry insert 22'''' shaped as a
generally flat tape having a compressible layer with a suitable
width. By way of example, dry insert 22'''' is made of a plurality
of filaments such as a plurality of generally continuous polyester
filaments grouped together by a matrix material, but the use of
other filament materials is possible. An optional compressible
layer is formed by, for instance, foaming the matrix material,
thereby providing a compressible layer 22b''''. In other
embodiments, the matrix material is not foamed so it doesn't
provide a compressible layer, but still provides the desired level
of coupling using friction. Additionally the matrix material is
used for attaching a plurality of water-swellable particles to dry
insert 22'''' for forming a water-swellable layer 22a''''. Suitable
foamed matrix materials include vinyls, polyurethanes,
polypropylenes, EVAs, or polyethylene blends. The plurality of
filaments and the matrix material are run through a die that forms
dry insert 22'''' into its desired shape such as a generally flat
ribbon-like profile. Dry inserts 22'''' may be run parallel to the
fiber ribbons in a sandwich configuration or have other
configurations such as helically wrapped about the optical fibers
or ribbon stack. Other similar constructions are possible using any
suitable materials for providing the compressible layer and the
water-swellable layer. Dry insert can include still other
constructions and/or materials such as sponge-like materials for a
compressible layer such as polyvinylalcohol (PVA).
[0040] Although cavity 28a is depicted with a generally rectangular
shape with a fixed orientation for housing the optical fiber
ribbon, other shapes and arrangements are possible such as
generally square, round, or oval. By way of example, cavity may be
rotated or stranded in any suitable manner along its longitudinal
length. The cavity can also have a partial oscillation through a
given angle, for instance, the cavity can rotate between a
clockwise angle that is less than a full rotation and then rotate
counter-clockwise for less than a full rotation. Furthermore, one
or more cavities may be offset towards one of the major surfaces,
thereby allowing easy opening and access from one side. The cavity
of a manufactured cable may have a slightly distorted (i.e.,
rounded or deformed) cross-section since it is difficult to
maintain the sharp edges during manufacturing.
[0041] Cables according to the present invention may have any
suitable dimensions, constructions, and/or fiber counts for the
given application. By way of example, in distribution applications
the width of the cable is preferably about 20 millimeters or less
and the height of the cable is preferably about 12 millimeters or
less. In drop applications, the width of the cable is preferably
about 10 millimeters or less and the height of the cable is
preferably about 5 millimeters or less. Of course, other cables of
the present invention can have other sizes and/or structures for
the given application depending on the requirements and fiber count
of the cable. For instance, cables of the present invention may
have larger dimensions for the major dimension, the minor
dimension, and/or different structures such as a toneable portion
as shown in FIGS. 6A and 6B for locating the cable in buried
applications. Likewise, cable jackets and/or other cable components
may be formed from a flame-retardant material and/or the cable can
have a flame-retardant characteristic, thereby making it suitable
for indoor applications such as multi-dwelling units (MDUs) or the
like.
[0042] Besides being a dry cable design, the cable of FIGS. 2A and
2B is also advantageous because it can be easily accessed from
either of the generally planar sides of the cable, thereby allowing
access to the desired optical fiber. In other words, ribbons from
either side of the ribbon stack, i.e., top or bottom, can be
accessed by opening the cable at the respective planar side.
Consequently, the craftsman or automation process has simple and
easy access to the cavity 28a by running a utility blade or cutting
tool along the length of the cable without cutting into strength
members, thereby allowing entry to cavity while inhibiting damage
to the optical fibers and/or strength members during the access
procedure. In other words, the craftsman can simply cut into cable
jacket by slicing the cable jacket and may use strength members as
a guide for the blade or cutting tool, thereby exposing cavity
during the cutting and allowing access to the at least one optical
fiber therein. Thus, the optical fibers in the cables of the
present invention may be easily, quickly, and repeatably accessed
by a craftsman or likewise in an automated process. Additionally,
the generally flat major surfaces of the cables are advantageous
because they allow for a smaller cable footprint and uses less
jacket material compared with round cables. Although the cable
depicted in FIGS. 2A and 2B is a generally flat dry cable design
having the fiber optic ribbon disposed between two dry inserts
having a foam tape with a laminated water-swellable tape, the
concepts of the invention are possible with other cable
configurations.
[0043] FIGS. 4A and 4B depict another cable 10 that is similar to
the cable of FIGS. 2A and 2B, but only includes a single dry insert
42 within cavity 28a of cable jacket 28. As shown, in FIG. 4A, dry
insert 42 and optical fiber ribbon 13 are, generally speaking
loosely disposed within cavity 28a within the A-region, thus there
is little to no coupling provided by this region (i.e., there is a
vertical free space within the cavity). On the other hand, the
B-region depicted by FIG. 4B provides the coupling since dry insert
42 is compressed within cavity 28a for providing a predetermined
level of coupling. Dry insert can be compressed within the cavity
to provide coupling using one or more methods. For instance, one
method for compressing the dry insert 42 is by reducing the height
of cavity 28a, thereby providing the desired degree of coupling.
Dry insert 42 provides another method for providing coupling by
using a thickness variation along the longitudinal length of dry
insert 42. For instance, FIG. 10 is a side view of dry insert 42
showing a thickness that varies along its longitudinal length.
Simply stated, dry insert 42 has a portion with a first thickness
T1 and a portion with a second thickness T2 where the first
thickness T1 is greater than the second thickness T2. The portion
of dry insert 42 that has first thickness T1 forms a portion of the
B-region of the cable since the dry insert thickness is compressed
when disposed within the cavity 48a with the optical fiber ribbon
13. By way of example, dry insert 42 can have a dry insert
thickness ratio defined as the second thickness T2 divided by the
first thickness T1 with the dry insert thickness ratio (T2/T1)
being between about 50% and 90%. By way of a numerical
illustration, a nominal first thickness for the A-region of dry
insert 42 is about 3.5 millimeters and a nominal second thickness
for the B-region of dry insert 42 is about 4.5 millimeters, thereby
yielding a dry insert thickness ratio of about 77%. Moreover, the
thickened portion of dry insert 42 can have any suitable length
and/or period along the length of same. Also, like dry insert 22,
dry insert 42 can be formed from any suitable material,
construction, or the like.
[0044] FIGS. 5A and 5B depict another cable that is similar to the
cable of FIGS. 2A and 2B, but it depicts a plurality of dry inserts
22' disposed within a cavity 28a of cable jacket 28 along with a
toneable lobe 58b that is useful for locating the cable in buried
applications while still allowing for a dielectric main cable body
58a. As shown, the cable has four dry inserts 22' disposed within
cavity 28a to cushion, couple and provide water-blocking.
Specifically, dry inserts 22' are generally disposed to sandwich
optical fiber ribbon therebetween, but the dry inserts 22' may
migrate within cavity 28a to other positions. FIG. 5B shows a
cross-sectional view of cavity 58a being constricted at the
B-region. Additionally, other suitable inserts may be used with
this cable or any other cable.
[0045] Toneable lobe 58b includes a conductive wire 55 disposed
within toneable lobe 58b. By way of example, conductive wire 55 is
a 24-gauge copper wire that allows the craftsman to apply a toning
signal thereto for locating the cable so it can be located or have
its location marked to prevent inadvertent damage. A cable jacket
58 and jacket portion of toneable lobe 58b are typically
co-extruded simultaneously using the same extrusion tooling. As
shown, toneable lobe 58b is connected with cable jacket 58 of the
main cable body 58a by a frangible web (not numbered) so that
toneable lobe 58b can easily be separated from main cable body 58a
for connectorization or other purposes. Specifically, the web of
toneable lobe 58b can include a preferential tear portion (not
visible) using suitable geometry for controlling the location of
the tear between the toneable lobe 58b and the main cable body 58a.
Toneable lobe 58b preferably tears away from the main cable body
cleanly so that it does not leave a ridge thereon, thereby allowing
for a profile that permits easy sealing with a connector boot or
the like. Using toneable lobe 58a is advantageous because if the
cable is struck by lightning the toneable lobe 58a would be
damaged, but the main cable body 58a would not be significantly
damaged since it is dielectric. Consequently, the cable is toneable
without requiring the labor and hardware necessary for grounding
the cable. Of course, other cables of the present invention may
also include a toneable lobe.
[0046] FIGS. 6A and 6B depict another cable 10 that is similar to
the cable of FIGS. 2A and 2B, but it uses a slightly different
jacket shape to improve side crush performance. Additionally, the
dry inserts 22,23 of this embodiment do not include a
water-swellable characteristic, but instead the cable includes a
small quantity of water-swellable powder (not visible) disposed
within a cavity 28a for inhibiting the migration of water therein.
This cable provides improved side crush performance since cable
jacket 28 has an upper concave wall (not numbered) and a lower
concave wall (not numbered) for improving side-crush strength for
the cable. Concave walls mean that the wall has an outer surface
that is generally concave with a generally uniform wall thickness
(i.e., the inner surface of the wall is curved to match the outer
surface.) In other words, the concave walls increase the cables
resistance to side-crush loads and helps preserves optical
performance during the same. Other cables of the present invention
may also use this concept.
[0047] FIGS. 7A and 7B depict another cable 10 that is similar to
the cable of FIGS. 2A and 2B, but it further includes an armor
layer 77 disposed between a cable jacket 28 and a second jacket 79.
Armor layer 77 provides rodent protection and/or additional crush
strength for the cable. Specifically, the cable includes an optical
fiber ribbon 13 disposed within a cavity 28a of cable jacket 28.
Strength members 24 are attached to cable jacket 28 and disposed on
opposite side of cavity 28a. Armor layer 77 is disposed about cable
jacket 28 and is shown with a butting seam, but it may have an
overlapping seam. Thereafter, second jacket 79 is applied over
armor layer 77. Armor layer 77 may be formed from any suitable
material such as a dielectric such as a high-strength polymer or a
conductive material such as a steel tape. Moreover, the armor layer
may be, shaped, ribbed, corrugated or the like for improving its
crush strength and/or flexural performance of the cable. In other
embodiments, the cable has two armor layers with one armor layer
above the cavity and one armor layer below the cavity within a
single cable jacket. Additionally, the two armor layers within the
cable jacket may have respective curved end portions that generally
contact each strength member 24 so that any crush forces are
directed and/or transferred towards the same. Additionally, if a
conductive armor component is used, strength members 24 are
preferably also formed from a conductive material such as steel,
rather than a more expensive glass-reinforced plastic strength
member. Moreover, it is also possible to join or attach strength
member 24 with the armor layer 77 by gluing, crimping, welding, or
the like. Consequently, the properties of each cable jacket may be
tailored for performance such as coupling, tear resistance, or the
other properties. By way of example, cable jacket 28 may be a
linear low-density polyethylene (LLDPE) for tear resistance and
outer jacket 78 may be a medium or high density polyethylene for
durability and abrasion resistance; however, other suitable
materials may be used. In this embodiment, the cavity does not
include a tube therein and the minor cavity dimension is smaller
than the strength member dimension. Additionally, the cable may
include one or more optional ripcords (not visible) for opening the
cable and/or removing the armor layer.
[0048] FIGS. 8A and 8B depict still another cable 10 that is
similar to the cable of FIGS. 2A and 2B, but includes a plurality
of cavities 88a,88b for housing communication elements such as
optical fibers and/or copper wires. Using more than one cavity
allows for flexibility in the cable applications. Multiple cavities
can have similar or different sizes that are suited for the
particular application. As shown, cavities 88a,88b have similar
height dimensions, but have different widths dimensions, thereby
allowing different ribbon fiber counts in respective cavities
and/or other components. Specifically, cavity 88a is sized for a
plurality of fiber optic ribbons 13 that can be accessed for
distribution or the like along the cable and cavity 88b is sized
for a plurality of copper conductors 82. Other embodiments are
possible, for instance, the first cavity can have optical fiber
ribbons with 4-fibers and the second cavity can have optical fiber
ribbons with 12-fibers. FIGS. 8A and 8B also illustrates an
optional strength member 24 disposed between cavities 88a and 88b.
The optional strength member is advantageous if it desired to only
access one of the cavities when opening the cable by allowing a
stopping point and/or a guide for the cutting tool. The optional
strength member may be the same size as the outboard strength
members or it may have a different size. Moreover, the optional
strength member may have a shape other than round so that the major
cable dimension may be minimized. Other structures may be used for
aiding in opening only one of multiple cavities. For instance, one
or more cavities may be offset relative to the neutral axis that
passes through the center points of strength members 24. By way of
example, the cavity having the four fiber ribbons is easily
accessible from one major surface and the cavity having the twelve
fiber ribbons is easily accessible from the other major surface.
Moreover, one or more of the major surfaces may be marked (not
visible) to indicate which cavity is accessible from the given
surface. Of course, other cables configurations of the present
invention can also use more than one cavity.
[0049] FIGS. 9A and 9B depict still another cable 10 configured as
a round cable that includes loose optical fibers 12 and a plurality
of dry inserts 22 disposed within a tube 92. In this cable tube 92
has an inner diameter that changes from the A-region to the
B-region. Specifically, the A-region tube 92 has an inner diameter
ID1 that is changes to an inner diameter ID2 in the B-region,
thereby creating and/or increasing the coupling of optical fibers
12. In other words, a cavity 98a changes from a first cavity
cross-sectional area CA1 to a second cavity cross-sectional area
CA2, where the cavity cross-sectional ratio is between about 50%
and 90%. Although shown as a plurality of dry inserts other
embodiments can use a single dry insert that is generally disposed
about the optical fibers. Additionally, this cable includes a
plurality of strength members 92 that are configured as tensile
yarns disposed about tube 92 and a cable jacket 98 therearound.
[0050] Besides ribbons and loose optical fibers, other packaging
arrangements for the optical fibers are also possible such as
having a plurality of optical fiber modules (not shown). Optical
fiber modules organize and protect the plurality of optical fibers
12 within each module jacket that is extremely thin, flexible, and
easily tearable without tools. Consequently, optical fiber modules
can be routed out of the cavity of the cable while still having a
protective covering disposed about the optical fibers. By way of
example, the optical fiber module includes twelve colored optical
fibers 12, thereby forming a relatively high optical fiber packing
density. Moreover, optical fiber module allows access to individual
optical fibers within the module jacket without having to remove
the same from a ribbon matrix material. Preferably, module jackets
are formed from a material that is easily tearable without tools.
For instance, the module jacket is formed from a highly filled
material so that it is easily tearable by the craftsman merely
using his fingers to tear the same and it will not stick to colored
or tight-buffered optical fibers during manufacturing. Suitable
module jacket materials may include a polybutylene terephthalate
(PBT), a polycarbonate and/or a polyethylene (PE) material and/or
an ethylene vinyl acrylate (EVA) or other blends thereof having
fillers like a chalk or talc; however, other suitable materials are
possible such as a UV-curable acrylate. Modules may include other
suitable cable components therein such as a grease, water-swellable
yarn, suitable thread or tape, a ripcord, or other suitable
component. Additionally, the cavity of cable may include grease,
water-swellable yarn or tape, dry insert, and/or any other suitable
component as desired.
[0051] The concepts of the present invention may also be
implemented using cable having cavities that do not change
cross-sectional areas. FIG. 10 depicts a side view of a generic dry
insert 42 that changes thickness along its longitudinal length of
the same. Although dry insert 42 is depicted as having a
compressible layer 42a and a water-swellable layer 42b that are
laminated together such as a foam layer and a water-swellable layer
the concept is applicable to other suitable dry inserts.
Specifically, dry insert 42 has a first thickness T1 that is
greater than a second thickness T2. For instance, a dry insert
thickness ratio is defined as the second thickness T2 divided by
the first thickness T1. The dry insert thickness ratio (T2/T1) is
between about 50% and about 90%, but other values are possible.
FIGS. 11A and 11B depict another fiber optic cable 10 where a
cavity 118a has a similar cavity cross-sectional area CA1 (likewise
the cavity height CH1 is the similar) in both the A-region and the
B-region. Dry insert 42 can be formed with the first thickness T1
or an additional portion may be added to a dry insert having a
uniform thickness (as represented by the portion above the dashed
line), thereby forming the first thickness T1. In other words, an
additional portion of a compressible layer may be positioned and/or
attached to the dry insert having a generally uniform thickness at
the desired position/spacing, thereby creating dry insert 42. As
shown by FIG. 11A, optical fiber ribbons 13 are loosely disposed
within a cavity 118a of a cable jacket 118 where dry insert(s) 42
has a second thickness T2. On the other hand, optical fiber ribbons
13 are coupled within cavity 118a of cable jacket 118 where dry
insert(s) 42 have a first thickness T1. The concepts of this cable
design may be applied to other cable designs with or without
changing the cavity cross-sectional area.
[0052] FIG. 12 schematically illustrates an explanatory one-pass
manufacturing line 120 for tubeless fiber optic cables according to
the present invention such as shown in FIGS. 2A and 2B; however,
other variations of the concepts may be used to manufacture other
assemblies and/or cables according to the concepts of the present
invention. One pass manufacturing line 120 includes at least one
optical ribbon payoff reel 121, a plurality of dry insert payoff
reels 122, a plurality of strength member payoff reels 123, a
plurality of strength member capstans 124, a cross-head extruder
125, a water trough 126, one or more caterpullers 127, and a
take-up reel 129. Additionally, tubeless fiber optic cables may
further include an armor layer and a second cable jacket
therearound, thereby forming a tubeless fiber optic cable similar
the cable illustrated in FIGS. 7A and 7B. The armor layer and/or
second cable jacket can be manufactured on the same line or on a
second manufacturing line.
[0053] The explanatory manufacturing process includes paying-off at
least one optical fiber ribbon 13 and dry inserts 22,23 from
respective reels 131, 132, and 132 and the different methods for
forming the coupling features are discussed below. Only one payoff
reel for optical fiber ribbon 13 is shown for clarity. However,
manufacturing lines can include any suitable number of payoff reels
for one or more ribbons or optical fibers in order to manufacture
assemblies and/or cables according to the present invention.
Thereafter, dry inserts 22,23 are generally positioned about
optical fiber ribbon 13, thereby forming a cable core 21 (i.e., a
dry insert-ribbon composite stack or sandwich). Additionally,
strength members 24 are paying-off respective reels 123 under a
relatively high tension (e.g., between about 100 to about 600
pounds) using respective strength member capstans 124, thereby
elastically stretching strength members 24 (represented by the
arrows) so that ERL is produced in the tubeless fiber optic cable.
In other words, after the tension is released on strength members
24 they return to their original unstressed length (i.e. shorten),
thereby producing ERL such as up to 1.2% or more since the ribbons
were introduced into the cable with about the same length as
tensioned strength members and the ribbons were not stretched.
Stated another way, the amount of ERL produced is equal to about
the strength member strain (i.e., elastically stretching of the
strength member) plus any plastic shrinkage of the cable jacket
that may occur. The strength member strain can create a significant
amount of ERL or EFL in a one-pass production such as 10% or more,
25% or more, 50% or more, and even up to 80% or more of the total
ERL or EFL within the cable. Furthermore, elastically stretching of
the strength member is advantageous since it allows for a precise
control of the amount of ERL or EFL being introduced into the cable
and greatly reduces strength member pistoning since the finished
cable jacket is in compression instead of tension. For the
manufacture of the tubeless fiber optic cable 10 of FIGS. 2A and
2B, about 95% of ERL is introduced into the cable by elastically
stretching the strength members. Thereafter, cable core 21 and
strength members 24 are fed into cross-head extruder 125 where
cable jacket 28 is extruded about cable core 21 and strength
members 24, thereby forming the tubeless fiber optic cable 10. As
shown by FIG. 12, cable jacket is being applied about the optical
fibers and strength members by cross-head extruder 125 while the
strength members are elastically stretched. After extrusion, cable
10 is then quenched in water trough 126 while the strength member
is still elastically stretched, thereby allowing the cable jacket
to "freeze" on the stretched strength members. Tubeless fiber optic
cable 10 is pulled through the manufacturing line using one or more
caterpullers 127 and then wound onto take-up reel 129 under low
tension (i.e., the tensile force that elastically stretched the
strength members is released and strength members return to a
relaxed length thereby creating ERL or EFL in the cable). As
depicted in the box, one manufacturing line may be used to form a
tubeless fiber optic cable similar to tubeless fiber optic cable 10
as shown in FIGS. 7A and 7B. As shown, a second caterpuller 127 is
used for pulling the cable assembly as the armor layer 77 is
paid-off a reel 131 and formed about cable 10 using suitable armor
forming equipment (not depicted), and a second cable jacket 79 is
extruded thereover using a cross-head extruder 132. Thereafter, the
tubeless fiber optic cable armored cable passes into a second water
trough 134 before being wound-up on take-up reel 129. Additionally,
other cables and/or manufacturing lines according to the concepts
of the present invention are possible. For instance, cables and/or
manufacturing lines may include a water-swellable tape, yarn, or
the like; however, the use of one or more other suitable cable
components is possible.
[0054] If the coupling feature is formed merely by using dry insert
42 with a changing thickness then the explanatory manufacturing
line shown in FIG. 12 is suitable for making the fiber optic cable
of FIGS. 11A and 11B. However, if the coupling feature is provided
by changing the cavity cross-sectional area then additional
manufacturing complexity is required for the explanatory
manufacturing line of FIG. 12 as discussed below. FIGS. 13A and 13B
schematically depict one method using an exemplary extrusion
tooling 200 for changing the cavity cross-sectional area by
changing the amount of polymer provided during extrusion of the
B-region of the cable. Specifically, extrusion tooling 200 includes
a tip 202 and a die 204 that can allow more polymer into the cable
cross-section, thereby resulting in a smaller cavity cross-section.
More specifically, during manufacturing one or more portions of die
204 can move from a first position shown in FIG. 13A to a second
position shown in FIG. 13B, thereby allowing more of a molten
polymer 208 to pass into the cable cross-section. Additionally, the
extruder screw speed may have to increase to deliver more molten
polymer for the cable jacket. As shown in FIG. 13B, an upper
portion 204a of die 204 moves upward to allow more molten polymer
to flow and creating a thicker jacket wall thickness (i.e., a
smaller cavity) in the B-region of the cable. Since only the upper
portion 204a of die 204 moves the cavity formed is asymmetrical, if
both an upper and lower portion of die 204 moves then the cavity
more symmetrical. FIGS. 14A and 14B depict another method for
changing the cross-sectional shape of the cavity. As shown, FIG.
14A shows the extrusion tooling 200 and a deforming element 206 for
making cable in the A-region. When the B-region of the cable is
desired, deforming element 206 contacts the molten cable jacket 208
to deform the same, thereby changing the cavity cross-sectional
area. Other manufacturing methods are also possible. By way of
example, another method may use both a moveable die to increase
amount of molten material and then use one or more deforming
elements to create a change in cross-sectional shape. Further these
methods can be applied to tubes and/or round cable in order to
create the desired level of coupling.
[0055] Cables of the present invention are also useful as a portion
of a larger cable assembly that is useful for distributing optical
fibers toward the subscriber. The cable assemblies can be assembled
in the factory or they can be constructed in the field. A variety
of fiber optic assemblies may be constructed from fiber optic
cables of the present invention. For instance, FIG. 15 depicts
fiber optic cable assembly 110 that includes fiber optic cable 10
as a portion of a distribution cable assembly. As shown, a tether
cable 140 is attached to fiber optic cable 10 at a first end and
includes a protective covering 111 for covering the splice portion
between fiber optic cable 10 and tether cable 140. A second end of
tether cable 140 can include one or more ferrules attached thereto
and the ferrule may be a portion of a receptacle, plug, or the like
for plug and play connectivity. Illustratively, FIG. 15 depicts a
hardened plug connector 145 on the second end of tether cable 140.
Of course, the second end of tether cable 140 can have any suitable
configuration for connectivity such as splice-ready optical fibers,
a connector or a receptacle having a ferrule, a multi-port or the
like, thereby allowing the craft flexibility for downstream
connectivity. FIG. 16 depicts a fiber optic cable assembly 110'
similar to FIG. 15 but it includes a multi-port 160 having a
plurality of receptacles 160a attached to a second end of tether
cable 140. Likewise, other types and/or structures are possible for
fiber optic assemblies according to the concepts of the invention.
For instance, a hardened connector or receptacle could be directly
attached to the tubeless fiber optic cable.
[0056] It will be apparent to those skilled in the art that various
modifications and variations can be made in the cable and cable
assemblies of the present invention without departing from the
spirit or scope of the invention. For instance, cables or
assemblies of the present invention can include other cable
components such as ripcords, paper or mica tapes, a friction
element, and/or other suitable components. Thus, it is intended
that the present invention cover the modifications and variations
of this invention provided they come within the scope of the
appended claims and their equivalents.
* * * * *