U.S. patent application number 17/461038 was filed with the patent office on 2022-04-21 for telecommunications cabling system.
The applicant listed for this patent is CommScope Technologies LLC. Invention is credited to Eric Emmanuel ALSTON, William Alan CARRICO, Julian S. MULLANEY.
Application Number | 20220120991 17/461038 |
Document ID | / |
Family ID | |
Filed Date | 2022-04-21 |
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United States Patent
Application |
20220120991 |
Kind Code |
A1 |
ALSTON; Eric Emmanuel ; et
al. |
April 21, 2022 |
TELECOMMUNICATIONS CABLING SYSTEM
Abstract
A telecommunications cable jacket insertion system operates to
insert a telecommunication cable into a jacket after the jacket has
been separately extruded. The system includes a jacket having
structures for easily inserting a cable therein over a long
distance in a field location. The system can further include a tool
for facilitating the insertion of the cable into the jacket.
Further, a cabling system includes a cable assembly that is
disaggregated into a robust outer jacketing portion and a
manageable fiber optic cable portion. For regions of a cable
installation where a robust cable construction is desired, the
manageable fiber optic cable portion is sheathed or otherwise
contained within the robust outer jacketing portion. For regions of
a cable installation where a robust cable construction is not
needed, the manageable fiber optic cable portion extends beyond or
outside of the robust outer jacketing portion.
Inventors: |
ALSTON; Eric Emmanuel;
(Fuquay-Varina, NC) ; MULLANEY; Julian S.;
(Raleigh, NC) ; CARRICO; William Alan; (Raleigh,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CommScope Technologies LLC |
Hickory |
NC |
US |
|
|
Appl. No.: |
17/461038 |
Filed: |
August 30, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16686841 |
Nov 18, 2019 |
11105999 |
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17461038 |
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15815196 |
Nov 16, 2017 |
10481360 |
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16686841 |
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62423017 |
Nov 16, 2016 |
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62423030 |
Nov 16, 2016 |
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International
Class: |
G02B 6/44 20060101
G02B006/44 |
Claims
1. A system for inserting a telecommunications cable into a jacket,
the system comprising: a cable dispenser including a length of
telecommunications cable and a cable outlet through which the
telecommunications cable is dispensed; a length of jacket including
an interior passage and a slit running along the length of the
jacket; and a jacket insertion device including: a jacket guide
defining a jacket feeder channel, the jacket feeder channel
extending from a first end to a second end and configured to
receive a leading end of the length of jacket at the first end; and
a cable guide configured to guide the length of telecommunications
cable to pass at least a portion of the jacket feeder channel and
extend out from the second end of the jacket feeder channel, the
cable guide aligning the length of telecommunications cable with
the slit of the length of jacket passing through the jacket feeder
channel, wherein at least a portion of the length of
telecommunications cable is inserted into the interior passage of
at least a portion of the length of jacket through at least a
portion of the slit as the length of jacket and the length of
telecommunications cable move[[s]] past the jacket insertion device
in the a travel direction.
2. The system of claim 1, wherein the jacket guide includes a
jacket alignment device configured to be inserted into the interior
passage of the jacket as the jacket passes through the jacket
feeder channel in the travel direction.
3. The system of claim 1, wherein the cable guide includes a cable
inlet through which the telecommunications cable passes into the
jacket feeder channel.
4. The system of claim 3, wherein the cable inlet is arranged
between the first and second ends of the jacket feeder channel.
5. The system of claim 3, wherein the cable inlet is arranged to be
align the slit of the jacket.
6. The system of claim 2, wherein the jacket alignment device
includes a first jacket alignment element and a second jacket
alignment element, a cable inlet being disposed such that the
telecommunications cable passes between the first and second jacket
alignment elements within the jacket feeder channel.
7. The system of claim 6, wherein the first jacket alignment
element is configured to engage the interior passage of the jacket
at the leading end thereof, and the second jacket alignment element
is configured to engage the interior passage of the jacket as the
jacket is pulled out from the second end of the jacket feeder
channel.
8. The system of claim 6, wherein the second jacket alignment
element includes a curved portion adjacent the cable inlet, the
curved portion configured to maintain the communications cable at a
predetermined curvature and lead the communications cable toward
the second end of the jacket feeder channel.
9. The system of claim 6, wherein the cable guide includes a cable
guide groove provided in the second jacket alignment element along
the travel direction, the cable guide groove configured to guide
the telecommunications cable within the jacket feeder channel as
the telecommunications cable is pulled out from the second end of
the jacket feeder channel.
10. The system of claim 1, wherein the jacket guide includes a slit
guide configured to align the slit of the jacket with the
communications cable passing through a cable inlet, the slit guide
configured to open the slit as the jacket travels in the travel
direction.
11. The system of claim 1, wherein the cable dispenser is
configured to wind the telecommunications cable into a coreless
coil defining an interior winding surface and an exterior winding
surface, the interior winding surface defining a hollow interior,
and the cable dispenser further including a plurality of winding
separators at least partially embedded within the coil wherein the
length of telecommunications cable alternately passes on one of the
first and second sides of one winding separator and on the other of
the first and second sides of an adjacent winding separator.
12. (canceled)
13. The system of claim 11, wherein each of the plurality of
winding separators has a first end and a second end, the first end
extending into a hollow interior of the coreless coil, the second
end extending to the exterior winding surface of the coreless
coil.
14. (canceled)
15. The system of claim 13, wherein the first ends of at least some
of the winding separators are provided with a flared end for
preventing the cable from being prematurely unwound.
16.-18. (canceled)
19. A system for inserting a telecommunications cable into a
conduit, the conduit having a slot extending along a length of the
conduit, the system comprising: a cable dispenser storing a length
of telecommunications cable; and an insertion device configured to
guide the length of telecommunications cable from the cable
dispenser to the conduit through the slot of the conduit.
20. The system of claim 19, wherein the insertion device includes:
a jacket guide defining a jacket feeder channel, the jacket feeder
channel extending from a first end to a second end and configured
to receive a leading end of a length of jacket at the first end;
and a cable guide configured to guide the length of
telecommunications cable to pass at least a portion of the jacket
feeder channel and extend out from the second end of the jacket
feeder channel, the cable guide aligning the length of
telecommunications cable with a slit of the length of jacket
passing through the jacket feeder channel, wherein at least a
portion of the length of telecommunications cable is inserted into
an interior passage of at least a portion of the length of jacket
through at least a portion of the slit as the length of jacket and
the length of telecommunications cable move past the insertion
device in the travel direction, wherein the jacket guide includes a
jacket alignment device configured to be inserted into the interior
passage of the jacket as the jacket passes through the jacket
feeder channel in the travel direction, and wherein the cable guide
includes a cable inlet through which the telecommunications cable
passes into the jacket feeder channel.
21.-35. (canceled)
36. A cabling system comprising: a cable stored in a storage
device; and a field installable jacket configured to define an
interior passage for receiving the cable, the field-installable
jacket having an opening for receiving the cable into the interior
passage, the opening defined along a length of the
field-installable jacket.
37. The cabling system of claim 36, wherein the field-installable
jacket has a pushing edge, a receiving edge, and a flexible section
extending between the pushing edge and the receiving edge, the
interior passage defined by engaging the pushing edge with the
receiving edge; and wherein the field-installable jacket includes a
stiffening element provided to at least one of the pushing edge and
the receiving edge.
38. The cabling system of claim 37, wherein the stiffening element
includes a rod made of fiberglass or metal.
39. The cabling system of claim 37, wherein the pushing edge and
the receiving edge include hook elements that engage each other to
mate the pushing edge and the receiving edge.
40. The cabling system of claim 36, wherein the cable is
pre-connectorized.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Patent
Application Ser. No. 16/686,841, filed Nov. 18, 2019; which is a
divisional application of U.S. patent application Ser. No.
15/815,196, filed Nov. 16, 2017, now U.S. Pat. No. 10,481,360. U.S.
Ser. No. 15/815,196 claims the benefit of U.S. Patent Application
Ser. No. 62/423,017 titled TELECOMMUNICATIONS CABLE JACKET
INSERTION SYSTEM filed Nov. 16, 2016 and U.S. Patent Application
Ser. No. 62/423,030 titled TELECOMMUNICATIONS CABLING SYSTEM filed
Nov. 16, 2016. The disclosures of U.S. patent application Ser. No.
16/686,841; U.S. patent application Ser. No. 15/815,196; U.S.
Patent Application Ser. No. 62/423,017; and U.S. Patent Application
Ser. No. 62/423,030 are hereby incorporated by reference in their
entireties. A claim of priority is made to each of the
above-referenced applications.
BACKGROUND
[0002] Fiber optic networks are increasingly being extended and
expanded to satisfy customer demand for high speed voice, data and
video services. Fiber optic cables are a fundamental building block
for any fiber optic network. The structural design of fiber optic
cables has been driven at least in part by the inherent fragility
and breakability of optical fibers. Thus, a primary goal of a fiber
optic cable design is to provide adequate protection to optical
fibers such that the optical fibers are not broken or otherwise
damaged in the field (e.g., during installation or with use over
time).
[0003] To achieve this goal, fiber optic cables often include
robust outer jackets and relatively stiff reinforcing elements
(e.g., reinforcing rods formed by fiberglass reinforced polymers
such as fiberglass reinforced epoxy) which provide effective
protection for optical fibers contained within the jackets. This
type of design is particularly prevalent for outdoor rated fiber
optic cables, but generally applies to other types of fiber optic
cables as well. While traditional fiber optic cable design are
effective for providing optical fiber protection, such designs can
cause difficulties or inefficiencies in the area of cable
management. For example, many fiber optic cables are connectorized
in the factory and are not customized to have a specific length
equal to the intended length of cable ultimately needed in the
field. Instead, fiber optic cables are typically selected with
lengths longer than the intended or expected use length in the
field. When installed, the excess fiber optic cable is typically
coiled and stored, often in an enclosure. The bulky, robust nature
of traditional fiber optic cable causes sections of cable that have
been coiled for storage to be relatively large and awkward to
store.
SUMMARY
[0004] This disclosure relates to a system for inserting a
telecommunications cable. In one possible configuration and by
non-limiting example, a telecommunications cable is deaggregated
from a jacket, and the cable and the jacket are combined or merged
in a field location where the cable is to be routed. In some
examples, the cable is fed into the jacket as the jacket is
deployed along a predetermined path.
[0005] As a telecommunication cable, such as a fiber optic cable,
is delicate, the cable needs to be protected by a jacket or a
protective outer layer. A jacket is used to receive and protect the
cable along a desired path. In accordance with the present
disclosure, a cable and a jacket is separately provided in a field
location. As cables are relatively small in size (e.g., a cross
sectional diameter), the cables can be stored in a small package
and carried to field in the package. For example, cables can be
stored in a dispenser (either rotating or non-rotating) or any
other storage and dispensing device, such as a coil, reel, roller,
or spool) and carried to field. In certain examples, different
lengths of cables are prepared as different packages such that a
technician or installer can select and use a package containing a
desired length of cable. In certain examples, the cables are
preconnectorized at either or both of the ends thereof.
[0006] The jacket in accordance with the present disclosure has
structures for easily inserting a cable therein over a long
distance in a field location. Further, the jacket is configured to
be easily stored and carried to field, separately from a cable. In
the field, the jacket can be fed with a cable as the jacket is
deployed to a predetermined path. Once the cable is routed as
desired, the jacket can be cut to length and any remaining length
of the cable can be stored in place, such as an enclosure. Since
the jacket can be cut to length after a desired length of cable is
routed, a technician or installer does not need to know the exact
length of cable to be routed along the path.
[0007] In certain examples, the system can further include a tool
for facilitating the insertion of the cable into the jacket. The
tool is configured to feed a cable into a jacket as the jacket is
routed along a path by either pulling or pushing an assembly of the
cable and the jacket.
[0008] In certain examples, the system for installing a cable
includes a cable dispenser and a jacket insertion device associated
with the cable dispenser and configured to insert a
telecommunications cable laterally to an extruded jacket.
[0009] For example, one aspect is a system for inserting a
telecommunications cable into a jacket. The system includes a
non-rotating cable dispenser, a length of jacket, and a jacket
insertion device. The non-rotating cable dispenser is configured to
store a length of telecommunications cable and includes a cable
outlet through which the telecommunications cable is dispensed. The
cable dispenser is configured to wind the telecommunications cable
into a coreless coil defining an interior winding surface and an
exterior winding surface. The interior winding surface defines a
hollow interior. The cable dispenser further includes a plurality
of winding separators at least partially embedded within the coil.
The length of telecommunications cable alternately passes on one of
the first and second sides of one winding separator and on the
other of the first and second sides of an adjacent winding
separator. The length of jacket includes an interior passage and a
slit running along the length of the jacket. The jacket insertion
device includes a jacket guide defining a jacket feeder channel.
The jacket feeder channel extends from a first end to a second end
and is configured to receive a leading end of the length of jacket
at the first end. The cable guide is configured to guide the length
of telecommunications cable to pass at least a portion of the
jacket feeder channel and extend out from the second end of the
jacket feeder channel. The cable guide is configured to align the
length of telecommunications cable with the slit of the length of
jacket passing through the jacket feeder channel. At least a
portion of the length of telecommunications cable is inserted into
the interior passage of at least a portion of the length of jacket
through at least a portion of the slit as the length of jacket and
the length of telecommunications cable moves past the jacket
insertion device in the travel direction.
[0010] Another aspect is a method of inserting a telecommunications
cable into a jacket. The jacket having a longitudinal slit. The
method includes engaging a portion of the telecommunications cable
with a cable guide of a jacket insertion device such that the
portion of the telecommunications cable is placed within a jacket
feeder channel, the telecommunications cable being stored in and
dispensed from a cable dispenser; inserting a portion of the jacket
into the jacket feeder channel to align the portion of
telecommunications cable with the slit of the jacket; and pulling
the telecommunications cable and the jacket together to enable the
telecommunications cable to be laterally inserted into the jacket
through the slit of the jacket.
[0011] Yet another aspect is a system for inserting a
telecommunications cable into a conduit. The conduit has a slot
extending along a length of the conduit. The system includes a
non-rotating cable dispenser storing a length of communications
cable, and an insertion device configured to guide the
communications cable from the cable dispenser to the conduit
through the slot of the conduit.
[0012] Further, this disclosure relates to a cabling system and
method.
[0013] One aspect of the present disclosure relates to a cabling
system that can be configured to provide robust cabling sections
for regions of a cable installation that require enhanced optical
fiber protection and less robust, more flexible cabling sections
for regions of a cable installation (e.g., a cable storage section)
where less optical fiber protection is required). In one example,
the cabling system can include a cable assembly that can be
disaggregated into a robust outer jacketing portion and a
manageable fiber optic cable portion. For regions of a cable
installation where a robust cable construction is desired, the
manageable fiber optic cable portion is sheathed or otherwise
contained within the robust outer jacketing portion. For regions of
a cable installation where a robust cable construction is not
needed, the manageable fiber optic cable portion extends beyond or
outside of the robust outer jacketing portion. For the regions of
the cabling system that include the manageable fiber optic cable
portion alone, excess length of the manageable fiber optic cable
portion can be effectively managed by coiling or otherwise routing
the excess length of manageable fiber optic cable in a small
package (e.g., a small enclosure, a small spool, a small fiber
holding unit, etc.).
[0014] In one example, the robust outer jacketing portion can
include a polymeric outer jacket that may include one or more
strength members within a wall of the outer jacket. The outer
jacket can define a passage for receiving the manageable fiber
optic cable portion. In one example the strength members can
include relatively rigid rods such as fiberglass reinforced polymer
rods, metal rods or like structures. Such rods can have sufficient
stiffness to limit or prevent excessive bending of the outer jacket
so that bend radius requirements of the manageable fiber optic
cable portion present therein are maintained. Such rods can also
have sufficient column strength to allow the outer jacket to be
pushed along a routing path (e.g., through a conduit/sleeve) during
installation and/or enough tensile strength to be pulled along a
routing path (e.g., through a conduit/sleeve) during installation.
More flexible strength members such as yarns or tapes (e.g., Aramid
yarns or tapes) can also be used in some examples. In preferred
examples the outer jacket defines a longitudinal slit (e.g., seam,
slot, opening, etc.) that allows the outer jacket to be opened
along its length such that the manageable fiber optic cable can be
laterally loaded therein (e.g., zipped in, plowed in or otherwise
inserted therein through a side of the outer jacket). In a
preferred example, the longitudinal slit includes an interlocking
longitudinal interface providing a mechanical interlock that
retains the slit in a closed configuration after the manageable
fiber optic cable has been loaded within the outer jacket. In one
example, the outer jacket portion has a maximum cross-dimension
that is at least 2, 3, 4 or 5 times as large as a corresponding
maximum cross-dimension of the manageable fiber optic cable
portion. In one example, the manageable fiber optic cable portion
is at least 2, 3, 4 or 5 times more flexible than the outer
jacketing portion.
[0015] It is preferred for the manageable fiber optic cable portion
includes fiber optic cable that is smaller, more flexible and more
lightweight (e.g., less robust) than the outer jacketing portion.
In one example, the fiber optic cable portion is only a coated
optical fiber. Such a coated optical fiber includes a core, a
cladding layer and at least one polymeric coating (e.g., acrylate
or other polymer). Such a coated optical fiber can also include a
core, a cladding layer and multiple protective layers (e.g., an
initial coating layer such as acrylate covered by an outer buffer
layer). In certain examples, the manageable fiber optic cable is a
micro-cable. In certain examples, the manageable fiber optic cable
includes an optical fiber including a core, a cladding layer and a
coating; and also includes a cable jacket and a tensile strength
structure (e.g., one or more strength members or layers). The
tensile strength structure can be positioned between the optical
fiber and the cable jacket of the manageable fiber optic cable. The
tensile strength member can be configured to provide tensile
strength without providing meaningful compressive strength. The
tensile strength member can be highly flexible to allow the
manageable fiber optic cable to be bent along a relatively tight
radius to enhance the ability to store the manageable fiber optic
cable in a small volume or package. In certain examples the tensile
strength member can include a yarn or yarn-like strength element
(e.g., Aramid yarn) or a tape or tape-like strength element. In
certain examples, the manageable fiber optic cable has a minimum
bend radius less than 100 mm. In other examples, the manageable
fiber optic cable has a minimum bend radius of around 2-5 mm. In
certain examples, the manageable fiber optic cable has a maximum
cross-dimension or outer diameter less than or equal to 4, 3, 2 or
1 millimeters. In certain examples, opposite ends of the manageable
fiber optic cable can be preconnectorized (e.g., the connectors can
be installed at the factory or in a controlled manufacturing
setting) prior to installation of the cabling system in the field.
In certain examples, the manageable fiber optic cable (e.g., the
connectorized manageable fiber optic cable) can be managed
separately from the outer jacketing structure by a storage device
capable of storing the manageable fiber optic cable in a relatively
small volume and capable of allowing the manageable fiber optic
cable to be readily paid out from the storage device during
deployment of the cabling system. In certain examples, the storage
device can include a rotatable spool that rotates as the manageable
fiber optic cable is paid out, or a containment device that allows
the manageable fiber optic cable to be paid out without rotation of
the containment device.
[0016] In use of the cabling system, the outer jacketing portion
and the manageable fiber optic cable portion are delivered in
disaggregated state to an installation site in the field. For
example, the outer jacketing portion can be delivered coiled about
a relatively large spool and the manageable fiber optic cable
portion can be delivered within or on a separate management device.
During installation, the manageable fiber optic cable portion is
loaded laterally into the outer jacketing portion (e.g., through a
longitudinal slit) to provide an aggregated portion of the cabling
assembly. By aggregating the outer jacket portion and the
manageable fiber optic cable portion, the robust nature of the
outer jacket portion can be used to protect the manageable fiber
optic cable portion during installation/routing and can also be
used to effective push or pull the cabling system along the desired
routing path (e.g., through a sleeve or other structure). Once the
aggregated portion of the cabling system has been installed along
the desired routing path, the outer jacketing portion can be cut to
length. In this way, the length of the outer jacketing portion can
be customized in the field so that excess length of the outer
jacketing portion need not be managed and stored. After
installation, the manageable fiber optic cable portion can extend
beyond the ends of the outer jacketing portion. The flexible and
small nature of the manageable fiber optic cable portion allows it
to be efficiently and effectively managed and stored. The length of
the manageable fiber optic cable portion need not be customized.
Instead, the manageable fiber optic cable portion can be
pre-connectorized with a standard length longer than the length of
the intended installation path, and the excess length of the
manageable fiber optic cable portion can be efficiently stored by a
management device having a relatively small volume.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 schematically illustrates a system for inserting a
telecommunications cable into a jacket in accordance with an
exemplary embodiment of the present disclosure.
[0018] FIG. 2 schematically illustrates an example jacket insertion
device of FIG. 1.
[0019] FIG. 3 is a flowchart illustrating an example method for
inserting a telecommunications cable into a jacket using the system
of FIG. 1.
[0020] FIG. 4 illustrates an example step of the method of FIG.
3.
[0021] FIG. 5 illustrates an example step of the method of FIG.
3.
[0022] FIG. 6 illustrates an example step of the method of FIG.
3.
[0023] FIG. 7 illustrates an example step of the method of FIG.
3.
[0024] FIG. 8 illustrates an example step of the method of FIG.
3.
[0025] FIG. 9 illustrates an example step of the method of FIG.
3.
[0026] FIG. 10 illustrates an example cable cover.
[0027] FIG. 11 is a cross sectional view of the cable cover of FIG.
10.
[0028] FIG. 12 is a schematic top view of a first embodiment of a
packaged cable dispenser including a coreless wound coil disposed
in a package having exemplary features of aspects in accordance
with the principles of the present disclosure.
[0029] FIG. 13 is a perspective view of a packaged cable dispenser
similar to that shown in FIG. 12, but with a round package.
[0030] FIG. 14 is a perspective view of a packaged cable dispenser
similar to that shown in FIG. 12, but with fewer winding
separators.
[0031] FIG. 15 is a schematic top view of a flat layout of the
coreless wound coil shown in FIG. 12.
[0032] FIG. 16 is a perspective view of a physical example of the
packaged cable dispenser of FIG. 12.
[0033] FIG. 17 is a top view of the packaged cable dispenser of
FIG. 16.
[0034] FIG. 18 is a bottom view of the packaged cable dispenser of
FIG. 17.
[0035] FIG. 19 is a perspective view of the packaged cable
dispenser of FIG. 17 with the top wall removed from the
housing.
[0036] FIG. 20 is a top view of the packaged cable dispenser of
FIG. 17 with the top wall removed from the housing.
[0037] FIG. 21 is a side view of the packaged cable dispenser of
FIG. 17.
[0038] FIG. 22 is an exploded perspective view of the packaged
cable dispenser of FIG. 17.
[0039] FIG. 23 is a top perspective view of a winding separator of
the packaged cable dispenser of FIG. 17.
[0040] FIG. 24 is a bottom perspective view of the winding
separator shown in FIG. 23.
[0041] FIG. 25 is a top view of the winding separator shown in FIG.
23.
[0042] FIG. 26 is a first side view of the winding separator shown
in FIG. 23.
[0043] FIG. 27 is a second side view of the winding separator shown
in FIG. 23.
[0044] FIG. 28 is a top perspective view of a payout tube of the
packaged cable dispenser of FIG. 23.
[0045] FIG. 29 is a bottom perspective view of the payout tube
shown in FIG. 23.
[0046] FIG. 30 is a first side view of the winding separator shown
in FIG. 23.
[0047] FIG. 31 is a second side view of the winding separator shown
in FIG. 23.
[0048] FIG. 32 is a top view of the winding separator shown in FIG.
23.
[0049] FIG. 33 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a first state.
[0050] FIG. 34 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a second state.
[0051] FIG. 35 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a third state.
[0052] FIG. 36 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a fourth state.
[0053] FIG. 37 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a fifth state.
[0054] FIG. 38 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a sixth state.
[0055] FIG. 39 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a seventh state.
[0056] FIG. 40 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in an eighth state.
[0057] FIG. 41 is a perspective view of the packaged cable
dispenser of FIG. 17 while dispensing cable in a ninth state.
[0058] FIG. 42 schematically illustrates a cabling system in
accordance with an exemplary embodiment of the present
disclosure.
[0059] FIG. 43 is a schematic cross sectional view of an example
jacket portion of the cabling system, taken along line A-A of FIG.
42.
[0060] FIG. 44 is a schematic cross sectional view of an example
cable portion of the cabling system, taken along line B-B of FIG.
42.
[0061] FIG. 45 is a schematic cross sectional view of another
example cable portion of the cabling system, taken along line B-B
of FIG. 42.
[0062] FIG. 46 schematically illustrates an example application of
the cabling system of FIG. 42.
[0063] FIG. 47 is a perspective view of yet another example of a
jacket in accordance with the present disclosure.
[0064] FIG. 48 is a cross sectional view of the jacket of FIG. 47
where the jacket is expanded.
[0065] FIG. 49 is a cross sectional view of the jacket of FIG. 47
where the jacket is assembled with a cable.
[0066] FIG. 50 schematically illustrates an example tool for
facilitating the assembly of the jacket with a cable.
[0067] FIG. 51 is a perspective view of yet another example of a
jacket in accordance with the present disclosure.
[0068] FIG. 52 is a perspective view of the jacket of FIG. 51 where
the jacket is assembled with a cable.
[0069] FIG. 53 is a flowchart of an example method for installing a
cable with a jacket in field.
DETAILED DESCRIPTION
[0070] Various embodiments will be described in detail with
reference to the drawings, wherein like reference numerals
represent like parts and assemblies throughout the several
views.
[0071] In general, the present disclosure relates to a system and
method for inserting a telecommunication cable into a jacket after
the jacket has been extruded. In some examples, the system includes
a jacket having structures for easily inserting a cable therein
over a long distance in a field location. The system can further
include a tool for facilitating the insertion of the cable into the
jacket. The jacket (as the flexible sleeve) can be provided as
coiled on a large bulk roll for easy storage and transportation to
a field location. Once carried to a field location, the jacket can
be rolled out, and the cable can be inserted into the jacket or
wrapped around by the jacket. In certain examples, a remaining
cable that is not assembled with the jacket can be stored in a
desired place, such as within a storage device or an enclosure.
[0072] In other examples, the system includes a cable dispenser and
a jacket insertion device. A jacket is made of a flexible material
and has a longitudinal slit through which the cable is inserted
into the jacket. The jacket is configured such that the slit is
flexed open as the cable is engaged with the slit, and returns to
the original form once the cable is inserted into the jacket. The
jacket can be stored in a spool. The jacket provides a conduit for
distributing cables. The cable is pulled from the cable dispenser
and engaged with the jacket insertion device. The jacket is pulled
from the spool and inserted into the jacket insertion device. The
cable and the jacket are simultaneously pulled through the jacket
insertion device that laterally loads the cable into the jacket and
presses the jacket closed. Once an appropriate length has been
deployed, the jacket can be cut to length. While the various
aspects of the present disclosure are useful for fiber optic
cables, the aspects are also applicable to other types of
telecommunications cables, such as copper cables. In other
examples, a plurality of cables (e.g., fibers) can be installed
within the extruded jacket in the same manner.
[0073] FIG. 1 schematically illustrates a system for inserting a
telecommunications cable into a jacket in accordance with an
exemplary embodiment of the present disclosure. The
telecommunications cable jacket insertion system is generally
designated as reference number 100. The system 100 includes a cable
dispenser 102, a length of telecommunications cable 104, a length
of jacket 106, and a jacket insertion device 108.
[0074] The cable dispenser 102 is configured to store a length of
telecommunications cable and dispense at least a portion of the
telecommunications cable. The cable dispenser 102 includes a cable
outlet 112 (e.g., a payout tube 512 as described below) through
which the telecommunications cable is dispensed. The cable
dispenser 102 is configured in various manners. In some examples,
the cable dispenser is a non-rotating dispenser. Examples of such
non-rotating cable dispensers are described and illustrated with
reference to FIGS. 12-41. In other examples, the cable dispenser
102 includes a reel or any rotatable device for winding a length of
telecommunications cable and dispensing at least a portion of the
cable.
[0075] In some examples, the telecommunications cable 104 includes
a length of fiber optic cable. For example, the cable 104 can be a
micro fiber optic cable. The telecommunications cable 104 can be
ferrulized or connectorized with a connector 122 at a leading end
of the cable. In other examples, the cable 104 can be of other
types, such as copper cables.
[0076] The connector 122 (or a ferrule or subassembly thereof) is
configured to have a small cross-sectional profile. One example of
the connector 122 is disclosed in U.S. Pat. No. 9,182,567, titled
FIBER OPTIC CONNECTOR WITH FIELD INSTALLABLE OUTER CONNECTOR
HOUSING AND KEYED FERRULE HUB, issued Nov. 10, 2015, the disclosure
of which is hereby incorporated by reference in its entirety. In
general, the connector 122 includes a ferrule for receiving an
optical fiber, a hub supporting the ferrule, a mounting block, a
strain relief sleeve, and an outer connector housing. The ferrule
has a front end face. The strain relief sleeve is configured to
interlock with the mounting block and provide bend radius
protection to the optical fiber. The outer connector housing has a
front end forming a plug portion and a rear end configured to
enable loading of the ferrule and the hub into the outer connector
housing through the rear end. The front end of the outer connector
housing provides access to the front end face of the ferrule when
the ferrule and the hub have been loaded into the outer connector
housing. The outer connector housing operates to interlock with the
mounting block such that the mounting block is secured at the rear
end of the outer connector housing and the ferrule and the ferrule
hub are retained within the outer connector housing by the mounting
block. The hub can be keyed with respect to the outer connector
housing such that hub can be inserted into the outer connector
housing in only one rotational orientation. The smaller ferrule or
connector 122 at the tip of the cable 104 can improve operation of
the insertion device 108.
[0077] The jacket 106 is configured to receive the cable 104 and
hold, protect, and/or conceal the cable 104 therein. The jacket 106
is configured to be field-installable such that the cable and the
jacket are brought separately to a field location and then the
cable is inserted into the jacket as needed. Such jackets can
create surface mounted pathways when existing concealed pathways
cannot be obtained or created. In this document, the jacket 106 can
also be referred to as an extrusion, conduit, raceway, or
molding.
[0078] As also shown in FIG. 2, the jacket 106 is configured as a
split tube to which a cable is laterally inserted. Once the cable
is inserted, the jacket 106 surrounds the cable. In some examples,
the jacket 106 defines an interior passage 132 along the length of
the jacket 106 to receive the cable 104 therein. Further, the
jacket 106 has a slit 134 that runs along the length of the jacket
106 for allowing post-extrusion insertion of the telecommunications
cable 104 into the interior passage 132. The slit 134 allows the
jacket 106 to be spread-apart to allow the cable 104 to be inserted
within the interior passage 132 of the jacket 106. After insertion
of the cable 104 into the passage 132, the slit 134 can be held
closed by the inherent mechanical properties of the jacket 106,
which bias the slit to a closed position. Additional structure can
also be used to assist in holding the slit 134 closed after
insertion of the cable 104. For example, adhesives or other bonding
agents can be used to bond together the opposing portions of the
jacket that define the slit 134. In other embodiments, a
reinforcing sheath can be mounted over the jacket 106 after
insertion of the cable 104 to prevent the slit from opening.
[0079] In some examples, the jacket 106 is manufactured from an
extrudable base material such as an extrudable plastic material.
Example base materials for the jacket include conventional
thermoplastic polymers such as Alcryn.RTM. Melt-Processible Rubber
sold by Advanced Polymer Alloys (a division of Ferro Corporation),
polyethylene, polypropylene, ethylene-propylene, copolymers,
polystyrene, and styrene copolymers, polyvinyl chloride, polyamide
(nylon), polyesters such as polyethylene terephthalate,
polyetheretherketone, polyphenylene sulfide, polyetherimide,
polybutylene terephthalate, low smoke zero halogens polyolefins and
polycarbonate, as well as other thermoplastic materials. Additives
may also be added to the base material. Example additives include
pigments, fillers, coupling agents, flame retardants, lubricants,
plasticizers, ultraviolet stabilizers or other additives. The base
material can also include combinations of the above materials as
well as combinations of other materials.
[0080] In some examples, the jacket 106 is paid out from a spool
140 that stores the jacket 106. As described herein, the jacket 106
can be manufactured as an extrusion in a continuous length, and is
wrapped about the spool 140 for storage. The continuous length of
the jacket 106 is dispensed from the spool 140 at work site and can
be cut to a desired custom length with or without the cable
104.
[0081] In some examples, the jacket 106 includes a cutout portion
136 at a leading end 138 of the jacket 106. As shown in FIG. 2, the
cutout portion 136 is configured to widen the slit 134 in the
travel direction D.sub.T so that the cable 104 is easily aligned
with, and enters, the slit 134 as the jacket 106 moves in the
travel direction through the jacket insertion device 108.
[0082] In some examples, the jacket 106 is used as a conduit, which
can be routed to telecommunications distribution housings and/or
panels. In one embodiment, the conduit is micro-conduit having a
nominal internal diameter between about 3 millimeters and 10
millimeters. The telecommunications cable 104 can be pulled from
either of the previously described and disclosed packaged cable
dispensers 102.
[0083] The jacket insertion device 108 is guide the cable and the
jacket and load the cable into the jacket as the cable and the
jacket are dispensed. An example of the jacket insertion device 108
is illustrated and described in more detail with reference to FIG.
2.
[0084] FIG. 2 schematically illustrates an example of the jacket
insertion device 108. The jacket insertion device 108 can include a
body 202, a jacket guide 204, and a cable guide 206.
[0085] The body 202 supports the jacket guide 204 and the cable
guide 206, and is configured to arrange the jacket guide 204 and
the cable guide 206 in place with respect to the cable dispenser
102. In some examples, the body 202 includes a mounting device 210
configured to fit the cable outlet 112 of the cable dispenser 102.
In the illustrated example, the body 202 is generally shaped as a
plate and mounted to the cable outlet 112 through the mounting
device 210 such that the body 202 lies in a plane in parallel with
the cable outlet 112. Other configurations of the body 202 are also
possible.
[0086] The jacket guide 204 is configured to guide the jacket 106
in a travel direction D.sub.T. The travel direction D.sub.T can be
generally transverse to the direction in which the cable outlet 112
extends (i.e., the direction in which a telecommunications cable
104 is dispensed). In the illustrated example, the travel direction
D.sub.T is generally at a right angle to the direction in which the
cable outlet 112 extends. In other examples, the travel direction
D.sub.T can be generally in parallel with the cable outlet 112. The
jacket guide 204 is arranged at a distance D1 from the end of the
cable outlet 112. The distance D1 can be determined based on
various factors, such as a minimum bend radius of the
communications cable (e.g., a fiber optic cable) being dispensed
through the cable outlet 112.
[0087] The jacket guide 204 includes a jacket feeder channel 212
extending from a first end 214 to a second end 216 of the jacket
guide 204. In some examples, the jacket feeder channel 212 is
defined by a hollow cylindrical wall 218 extending in the travel
direction D.sub.T between the first end 214 and the second end 216.
Other configurations are also possible in other examples. The
jacket feeder channel 212 is configured to receive the leading end
138 of the jacket 106 at the first end 214. As described below,
once the leading end 138 of the jacket 106 is engaged with the
jacket feeder channel 212 at the first end 214, the jacket 106 can
be pushed toward the second end 216 of the jacket feeder channel
212 in the travel direction D.sub.T until the leading end 138 of
the jacket 106 exits the second end 216. The leading end 138 of the
jacket 106 extending out from the second end 216 can be pulled out
at the second end 216 in the travel direction D.sub.T together with
the communications cable 104 while the cable 104 is contained
within the interior passage 132 of the jacket 106.
[0088] Although it is illustrated that the jacket feeder channel
212 extends generally along a straight line or axis (i.e., the
travel direction D.sub.T is generally straight), it is also
possible that the jacket feeder channel 212 is at least partially
curved (i.e., the travel direction D.sub.T can be at least
partially curved).
[0089] In some examples, the jacket guide 204 includes a jacket
alignment device 220 configured to be inserted into the interior
passage 132 of the jacket 106 as the jacket 106 passes through the
jacket feeder channel 212 in the travel direction D.sub.T. As
illustrated, the jacket guide 204 can be at least partially
disposed within the jacket feeder channel 212.
[0090] In some examples, the jacket alignment device 220 includes a
first jacket alignment element 222 and a second jacket alignment
element 224. The first jacket alignment element 222 is arranged at
or adjacent the first end 214 of the jacket guide 204, and the
second jacket alignment element 224 is arranged at or adjacent the
second end 216. As described below, the first jacket alignment
element 222 and the second jacket alignment element 224 are
arranged at least partially within the jacket feeder channel 212
such that the communications cable 104, which is routed through a
cable inlet 240 of the cable guide 206, passes between the first
jacket alignment element 222 and the second jacket alignment
element 224 within the jacket feeder channel 212.
[0091] The first jacket alignment element 222 is configured to
engage the interior passage 132 of the jacket 106 at the leading
end 138 of the jacket 106. In the illustrated example, the first
jacket alignment element 222 is configured as a cylindrical block
extending along the travel direction D.sub.T, which generally
conforms to the interior passage 132 of the jacket 106. The first
jacket alignment element 222 can include a cone portion 228 that
faces the leading end 138 of the jacket 106 that is pushed in the
travel direction D.sub.T. The cone portion 228 is shaped to be
easily inserted into the interior passage 132 of the jacket 106 as
the jacket 106 is inserted into the jacket feeder channel 212 at
the first end 214 of the jacket guide 204.
[0092] The second jacket alignment element 224 is configured to
engage the interior passage 132 of the jacket 106 as the jacket 106
is pulled out from the second end 216 of the jacket feeder channel
212. As illustrated, the second jacket alignment element 224 is
generally aligned with the first jacket alignment element 222 along
the travel direction D.sub.T. As described below, the second jacket
alignment element 224 is configured to contribute to the
configurations of the cable guide 206.
[0093] In some examples, the jacket guide 204 includes a window 230
for permitting a portion of the cable 104 to be laterally engaged
into the jacket feeder channel 212. In the illustrated example, the
window 230 is longitudinally formed to expose at least a portion of
the jacket feeder channel 212. For example, the window 230 is
configured to expose the second jacket alignment element 224
therethrough so that the cable 104 is laterally engaged with the
cable guide 206 associated with the second jacket alignment element
224 as described below. The window 230 is further configured to
open a cable inlet 240 of the cable guide 206 together with the
second jacket alignment element 224 so that the cable inlet 240 and
the second jacket alignment element 224 are simultaneously
accessible through the window 230.
[0094] In some examples, the jacket guide 204 further includes a
slit guide device 232 configured to align the slit 134 of the
jacket 106 with the cable 104 routed into the jacket feeder channel
212. In some examples, the slit guide device 232 can also open the
slit 134 so that the cable 104 is easily inserted therethrough. The
slit guide device 232 can be configured to connect the wall 218
with the first jacket alignment element 222 and/or the second
jacket alignment element 224. In some examples, the slit guide
device 232 is aligned with the cable inlet 240 along the travel
direction D.sub.T (or along a direction parallel with the travel
direction D.sub.T). In some examples, the slit guide device 232 can
be continuously formed between the wall 218 and the first and
second jacket alignment elements 222 and 224. In other examples,
the slit guide device 232 have discrete portions that at least
partially connect the wall 218 to the first jacket alignment
element 222, and/or discrete portions that at least partially
connect the wall 218 to the second jacket alignment element
224.
[0095] Referring still to FIG. 2, the cable guide 206 operates to
guide at least a portion of the length of telecommunications cable
104 to pass at least a portion of the jacket feeder channel 212 and
extend out from the second end 216 of the jacket feeder channel
212. The cable guide 206 is configured to route the communications
cable 104 from the cable outlet 112 of the cable dispenser 102 into
the jacket feeder channel 212 such that the communications cable
104 runs across the layer of the jacket 106 as the jacket 106
passes through the jacket feeder channel 212. In some examples, the
cable guide 206 is configured to align the telecommunications cable
104 with the slit 134 of the jacket 106 passing through the jacket
feeder channel 212. Accordingly, the cable guide 206 guides the
communications cable 104 to be laterally inserted into the interior
passage 132 of the jacket 106 through the slit 134 thereof.
[0096] As described below, when both of the leading end of the
communications cable 104 and the leading end 138 of the jacket 106
project out from the second end 216 of the jacket feeder channel
212, the telecommunications cable 104 and the jacket 106 can be
pulled out together from the jacket guide 204 in the travel
direction D.sub.T. As the cable 104 and the jacket 106 are pulled
out, the telecommunications cable 104 continues to be dispensed
from the cable dispenser 102 and the dispensed cable 104 is
inserted into the interior passage 132 of the jacket 106, which is
being supplied through the jacket guide 204, through the slit 134
of the jacket 106.
[0097] The cable guide 206 includes a cable inlet 240 through which
the cable 104 that has been dispensed from the cable outlet 112 of
the cable dispenser 102 is routed into the jacket feeder channel
212. In some examples, the cable inlet 240 is arranged between the
first end 214 and the second end 216 of the jacket guide 204. In
other examples, the cable inlet 240 is disposed such that the
telecommunications cable 104 passes between the first and second
jacket alignment elements 222 and 224 within the jacket feeder
channel 212.
[0098] In some examples, the cable inlet 240 is arranged to be
aligned with the slit 134 of the jacket 106 when the jacket 106
passes through the jacket feeder channel 212.
[0099] The cable inlet 240 is open on the same side of the window
230 of the jacket guide 204, so that the cable can be laterally
inserted into the jacket feeder channel 212 through the window 230
and the cable inlet 240 simultaneously.
[0100] The cable guide 206 can further include a cable guide groove
242 configured to guide the telecommunications cable 104 within the
jacket feeder channel 212 as the telecommunications cable 104 is
pulled out from the second end 216 of the jacket feeder channel
212. In some examples, the cable guide groove 242 is provided in
the second jacket alignment element 224. In the illustrated
example, the second jacket alignment element 224 is shaped as a
longitudinal cylindrical segment that extends along the travel
direction D.sub.T, and the cable guide groove 242 is formed on a
flat surface (i.e., a surface facing downwards in FIG. 2) of the
second jacket alignment element 224. In some examples, at least a
portion of the cable guide groove 242 is aligned with a center of
the jacket feeder channel 212 and extends along the travel
direction D.sub.T so that the cable 104 is positioned at the center
of the jacket feeder channel 212.
[0101] The cable guide 206 can further include a curved portion 244
adjacent the cable inlet 240. The curved portion 244 is provided
in, or formed as part of, the second jacket alignment element 224.
The curved portion 244 is configured to maintain the communications
cable 104 at a predetermined curvature and lead the communications
cable 104 toward the second end 216 of the jacket feeder channel
212. In some examples, the curvature is determined
[0102] In some examples, the cable inlet 240 has an edge 246 that
the cable 104 contacts as the cable 104 is pulled through the
jacket feeder channel 212. The edge 246 can have a slanted surface
that generally corresponds to the curvature of the curved portion
244 so that the cable 104 is smoothly conveyed along the cable
inlet 240 and the curved portion 244.
[0103] As such, the cable inlet 240 and/or the curved portion 244
can define a sufficient curve to maintain a minimum bend radius of
the cable 104 as the cable 104 are being paid out and fed into the
jacket feeder channel 212.
[0104] In some examples, the cable guide groove 242 is also formed
on the curved portion 244 of the second jacket alignment element
224 and extends toward the second end 216 of the jacket feeder
channel 212.
[0105] Referring to FIGS. 3-9, an example method of inserting a
telecommunications cable into a jacket. In particular, FIG. 3 is a
flowchart illustrating an example method 300 for inserting the
telecommunications cable 104 into the jacket 106 using the system
100 as described above. FIGS. 4-9 illustrate various steps of the
method 300 of FIG. 3.
[0106] As shown in FIG. 3, the method 300 can begins with operation
302 in which the jacket insertion device 108 is engaged with the
cable dispenser 102. In some examples, as illustrated in FIG. 2,
the jacket insertion device 108 is assembled with the cable
dispenser 102 by fitting the cable outlet 112 into the mounting
device 210. Other coupling methods can be used in the other
examples. In yet other examples, the jacket insertion device 108 is
not connected or coupled with the cable dispenser 102, and merely
disposed at a predetermined location apart from the cable dispenser
102.
[0107] At operation 304, a portion of the cable 104 is pulled out
from the cable dispenser 102 through the cable outlet 112. When the
cable 104 is dispensed, the cable 104 is terminated with a ferrule
or connector 122. In other examples, the ferrule or connector 122
is provided to the cable 104 before the cable 104 is pulled out
from the cable dispenser 102.
[0108] At operation 306, the portion the cable 104, which is pulled
out from the cable dispenser 102, is engaged with the jacket
insertion device 108. An example of this operation is illustrated
in FIG. 4. In some examples, the portion of the cable 104 that is
dispensed from the cable dispenser 102 is laterally inserted into
the jacket feeder channel 212 through the window 230, so that the
leading edge (e.g., the ferrule or connector 122) of the cable 104
is projected from the jacket insertion device 108.
[0109] At operation 308, a portion of the jacket 106 is inserted
into the jacket insertion device 108. An example of this operation
308 is illustrated in FIGS. 5 and 6. In some examples, as shown in
FIG. 5, the leading end 138 of the jacket 106 is inserted into the
jacket feeder channel 212 at the first end 214 of the jacket
insertion device 108. The jacket 106 can be inserted by hand (in
FIG. 5) or using a tool. As the jacket 106 passes through the
jacket feeder channel 212, the cable 104, which has been routed
through the cable inlet 240 and at least a portion of the jacket
feeder channel 212, remains stationary, and the leading end 128 of
the jacket 106 comes close to the cable 104 within the jacket
feeder channel 212. As described above, the jacket 106 is arranged
such that the slit 134 of the jacket 106 is aligned with the cable
104, using such as the slit guide device 232. As shown in FIG. 6,
the jacket 106 is further pushed in the travel direction D.sub.T
(by exertion of force F) so that the cable passage 132 of the
jacket 106 receives the cable 104 therewithin. As described above,
while the cable 104 is stationary, the jacket 106 is moved in the
travel direction D.sub.T such that a portion of the cable 104 at or
adjacent the cable inlet 240 is engaged with the slit 134 and a
portion of the cable placed within the jacket feeder channel 212 is
received within the cable passage 132 of the jacket 106. The jacket
106 is pushed until the leading end 138 is projected from the
second end 216 of the jacket insertion device 108.
[0110] Alternatively, the jacket 106 can be inserted into the
jacket insertion device 108 laterally through the window 230. For
example, a portion of the jacket 106 is inserted through the window
230 so as to wrap around the first jacket alignment element 222
and/or the second jacket alignment element 224. As the jacket 106
is inserted laterally through the window 230, longitudinal lips 142
and 144 of the jacket 106 that face each other at the slit 134 flex
apart and proceed into the jacket feed channel 212 around the first
jacket alignment element 222 and/or the second jacket alignment
element 224 in the opposite circular directions so that the jacket
106 wraps around the first jacket alignment element 222 and/or the
second jacket alignment element 224 when the jacket 106 is fully
inserted into the jacket insertion device 108.
[0111] At operation 310, the cable 104 and the jacket 106 are
pulled together away from the jacket insertion device 108. An
example of this operation is illustrated in FIGS. 7 and 8. As the
cable 104 and the jacket 106 are pulled in the travel direction
D.sub.T, the cable 104 and the jacket 106 are continuously supplied
into the jacket insertion device 108, and the cable 104 is inserted
into the cable passage 132 of the jacket 106 through the slit 134
within the jacket feeder channel 212 of the jacket insertion device
108. As described above, the jacket feeder channel 212 is
configured loads the cable 104 into the jacket 106 through the slit
134 and enables the jacket 106 to be closed at the slit 134.
[0112] Alternatively, in some embodiments, the jacket 106 is
pre-installed along a desired path, and the non-rotating cable
dispenser 120 and the jacket insertion device 108 can be moved
along the pre-installed jacket 106 to plow the cable 104 into the
jacket 106.
[0113] At operation 312, the cable 104 and the jacket 106 can be
cut to an appropriate length once such a length is deployed through
the jacket feeder channel 212. An example of this operation is
illustrated in FIG. 9.
[0114] Alternatively, in some embodiments, the jacket 106 and the
cable 104 are removed together laterally from the jacket insertion
device 108 through the window 230. The cable 104 and the jacket 106
can be laterally removed through the window 230 with or without
cutting the jacket and the cable to a length beforehand. For
example, as the jacket 106 with the cable 104 is removed laterally
through the window 230, the longitudinal lips 142 and 144 of the
jacket 106 flex apart and are pulled out from the jacket feed
channel 212 around the first jacket alignment element 222 and/or
the second jacket alignment element 224 in the opposite circular
directions. As such, the jacket 106 with the cable 104 can be
removed from the jacket insertion device 108 without cutting the
jacket 106 and the cable 104 beforehand.
[0115] Referring to FIGS. 10 and 11, a cable cover 400 is provided
to cover the connector 122 (i.e., the leading end of the cable 104)
along with the jacket 106. In some examples, the cable cover 400
includes a pulling eye 402 configured to encase the end of the
cable 104 inserted into the jacket 106.
[0116] In the illustration of FIGS. 4-11, the cable dispenser and
the insertion device is mounted at a fixed location, and the jacket
is pulled or moved relative to the cable dispenser and the
insertion device, so that the cable is pulled from the dispenser
and loaded into the jacket as the jacket moves past the cable
dispenser and the insertion device. However, in an alternative
example, the jacket or conduit can be pre-installed along a desired
path within a building or any installation location, such as
multi-dwelling units (MDUs). Then, the set of the cable dispenser
and the insertion device can be moved, either manually or by
another tool, along the pre-installed jacket to plow the cable
stored in the dispenser into the conduit.
[0117] Referring to FIGS. 12-41, the cable dispenser 102 are
described in more detail. As described herein, examples of the
cable dispenser 102 are disclosed in U.S. Patent Application
Publication No. 2016/0207723, titled Coreless Wound Coil Dispenser
with Optional Cable Storage for an Optical Terminal Network, filed
Dec. 18, 2015, the entirety of which is hereby incorporated by
reference.
[0118] Referring to FIG. 12, an example of the packaged cable
dispenser 102 is disclosed. FIG. 13 also shows a generally similar
packaged cable dispenser 102, but with a different packaging. As
shown, the dispenser 102 can have a coreless wound coil 500
disposed in a package 600. In one aspect, the coreless wound coil
500 includes a length of telecommunications cable 502 wound to
define an exterior winding surface 504 and an interior winding
surface 506 which further defines a hollow interior 508. In some
examples, the telecommunications cable 104 is configured as, or
includes, the telecommunications cable 502. In one example, the
wound coil 500 has an outside diameter equal to or less than about
5 inches, and preferably about 3 inches to about 31/2 inches. In
one example, the telecommunications cable 502 is a fiber optic
cable. Because the disclosed teachings provide for the formation of
a wound coil of fiber optic material that is coreless, the total
length of cable 502 that can be wound into a single coil can be
greater than what is obtainable for fiber optic cables wound about
a core structure. This is due to the circumstances that cumulative
hoop stresses exerted by the cable itself on more interior wound
loops near the core structure limit the total length of the cable.
As such forces are essentially entirely absent in a coreless wound
coil, once removed from the mandrel about which it is formed, the
disclosed teachings represent a significant improvement.
[0119] In one example, the cable 502 has a factory ferrulized end,
such as is described in Patent Cooperation Treaty (PCT) patent
application publication WO 2014/085459, the entirety of which is
hereby incorporated by reference. In such a case, optical
connectors can be later mounted to the ferrulized end of the cable
502, as explained in the WO '459 publication and as explained in
United States patent application publication US 2014/0153878 A1,
the entirety of which is hereby incorporated by reference. One or
both ends of the cable 502 can also be connectorized as explained
in U.S. Pat. No. 8,439,577, the entirety of which is hereby
incorporated by reference. It is also noted that since the
non-pulled end of the cable 502 can be pre-connectorized within the
package 600, as the wound coil 500 does not rotate within the
package 600 during dispensation.
[0120] In one example, the telecommunications cable 502 has a
nominal diameter of less than 3 milimeters (mm), a diameter of less
than 6 mm, and/or a diameter of less than 5 mm. In one example, the
cable 502 has a nominal diameter from about 800 to about 900
microns and includes a plurality of individual optical fibers of
about 650 microns. In one example, the telecommunications cable 502
has a pull rating sufficient to allow the cable 502 to be pulled
through a conduit without damaging the fibers, for example a pull
rating of about 300 Newtons. In one example, the telecommunications
cable 502 is provided with sufficient stiffness to allow the cable
502 to be pushed through a conduit, for example the cable 502 can
be provided with stiffening aramid fibers or steel wire.
[0121] In another aspect, the package 600 can include
interconnected sidewalls 602, 604, 606, 608 extending between a top
side 610 and a bottom side 612. The sidewalls 602, 604, 606, 608
can define an interior perimeter 620. As shown, the exterior
winding surface 504 of the wound coil 500 is within the interior
perimeter 620 of the package 600. The package 600 may be formed
from a variety of materials, such as plastic or a paper product.
The package 600 may be provided with a closable opening for
inserting the wound coil 500 within the package 600. Referring to
FIG. 13, the dispenser 102 is provided with a circular sidewall
602, in contrast to the square packaging shown in FIG. 12.
[0122] In the exemplary embodiment shown, the wound coil 500
further includes a plurality of winding separators 510, 512
embedded within the wound coil 500. The winding separators 510, 512
function to create and maintain the winding pattern of the wound
coil 500 by preventing migration of the cable 502 across the width
of the wound coil 500. In one example, the winding separators 510,
512 are provided with a curved or rounded profile to reduce
friction between the cable 502 and the separators 510, 512 as the
cable 502 is being unwound from the interior winding surface 506.
As shown, each of the winding separators 510, 512 extends
completely through the wound coil 500. To achieve this function,
the winding separators 510, 512 can be provided with a respective
first end 510a, 512a extending at least to the interior winding
surface 506 and a second end 510b, 512b extending at least to the
exterior winding surface 504. Each of the winding separators 510,
512 may also be provided with a respective first side 510c, 512c
and a respective opposite second side 510d, 512d.
[0123] With reference to FIG. 15, a flat layout schematic is
presented of the wound coil 500 shown in FIG. 12 to illustrate the
winding pattern of the coil 500 with respect to the winding
separators 510, 512. As shown in FIG. 15, a plurality of wraps of
the cable 502 are illustrated with a single wrap 502 being shown in
bold for the purpose of discussion herein. During each wrap or pass
of the winding process, the cable 502 is woven between the
separators 510, 512 such that the cable 502 alternately passes on
one of the first and second sides 510c, 512c, 510d, 512d of one
winding separator 510, 512 and on the other of the first and second
sides 510c, 512c, 510d, 512d of an adjacent winding separator 510,
512. Accordingly, for the embodiment shown in which five winding
separators 510, 512 are provided, the cable 502 passes on the first
side 510c of the first separator 510, then on the second side 510d
of the next separator 510, then on the first side 510c of the next
separator 510 (or 512d of separator 512), then on the second side
510d of the next separator 510, then on the first side 510c of the
last separator 510. As the winding process is continuous, the cable
502 will then pass on the second side 510d of the first separator
510 and the cable 502 will continue to be woven on the opposite
sides of the separators 510, 512 than the previous winding pass of
the cable 502. As long as the total number of winding separators
510, 512 is an odd number, the cable 502 will wind on opposite
sides of the separators with each alternating winding wrap. Such an
approach which will ensure that half of the cable 502 in the fully
wound coil 500 is wound onto each side of the separators 510, 512
in a balanced manner with the cable 502 crossing over the
previously wound segment between each winding separator 510, 512 to
prevent cable twist during removal of the cable 502. Although five
winding separators 510, 512 are shown, it should be understood that
more or fewer winding separators 510, 512 may be utilized, for
example, three, seven, nine, and/or eleven winding separators 510,
512. In one example, and as presented in FIG. 6B, a packaged cable
dispenser 102 having three winding separators, including a payout
tube 512 and two separators 510, is shown. It is noted that the use
of fewer separators 510, 512 will result in fewer cable cross-overs
for each wound loop and a lower density winding, which can be
beneficial for accommodating cables of larger diameters.
[0124] In the embodiment shown, winding separator 512 is shown as
being formed as a hollow payout tube 512 having a hollow interior
512e and extending through the sidewall 602 of the package. As
configured, the starting end 502a of the cable 502 is pulled from
the interior winding surface 506 of the wound coil and through the
interior 512e of the payout tube 512. Accordingly, the cable 502
can be pulled from the package through the payout tube 512 such
that the wound coil is paid out from the interior winding surface
506 towards the exterior winding surface 504. As the cable 502 has
been wound in the above manner, the cable 502 can be pulled from
the wound coil 500 without a twist being imparted onto the cable
502. In one aspect, the hollow interior 512e has an interior
dimension that is large enough to not unduly restrict the cable 502
as it is being pulled, but not so large that a potentially kinked
or knotted cable 502 could enter into the interior 512e. In one
example, the hollow interior 512e is no greater than twice the
diameter of the cable 502.
[0125] Referring to FIGS. 17-32, a physical example of the packaged
cable dispenser 102 schematically shown at FIGS. 12-16 is
presented. As shown, package 600 is configured as a generally
cylindrical-shaped housing 600. However, it should be appreciated
that numerous housing shapes are useful with the disclosed
teachings, for example, housings that have any of a number of
geometric shapes (e.g. ovular, triangular, square, rectangular,
pentagonal, hexagonal, octagonal, etc.). As shown, housing 600 has
a continuous sidewall 602 defining the interior perimeter 620. The
housing 600 is also provided with a bottom wall 612 adjoining the
sidewall 602. As shown, the bottom wall 612 and the sidewall 602
are integrally formed as a single component. However, the bottom
wall 612 could be formed as a separate component which is either
permanently or removably joined to the sidewall 602. The housing
600 can also be provided with a top wall 610. As shown, the top
wall 610 is removably attached to the sidewall 602, but could also
be permanently attached, if desired. The top wall 610 can be
secured to the sidewall 602 by tabs 614 provided on the sidewall
602 and by the first ends or top edges 616b of mounting or channel
members 616 (discussed later) provided on the sidewall 602. In one
aspect, the top wall 610 is connected to the sidewall 602 with a
snap-fit type of connection. Together, the sidewall 602, the top
wall 610, and the bottom wall 612 form an interior volume 614
within which the coreless wound coil 500 can be stored.
[0126] In one aspect, the winding separators 510 can be provided
with a first end 510a, a second end 510b, a first side 510c, and a
second side 510d. In the example shown at FIGS. 17-32, each of the
winding separators 510 can be provided with a stem portion 514
extending from a base portion 516. The stem portion 514 is shown as
extending between the first and second ends 510a and having the
base portion 516 attached at the second end. As shown, the stem
portion 514 and the base portion 516 are integrally formed as a
single component, but may be formed as separate components that are
later joined together.
[0127] The stem portion 514 of the winding separator 510 is flared
at the first end 510a such that the first end 510a has a thickness
t1 that is greater than a thickness t2 of the stem portion 514 at
the second end 510b. The flared first end 510a operates to retain
the cable 502 onto the winding separators 510 such that the cable
502 does not prematurely unravel with only one loop coming off the
separator 510 at a time. In one aspect, the flared first end 510a
can be provided with sloped portions 510e transitioning between the
first and second thicknesses t1, t2. The sloped portions 510e, 510f
can be configured to gently guide the cable 502 past the first end
510a while also preventing the cable 502 from becoming hung up or
caught on the first end 510a. Each winding separator 510 may also
be provided with rounded portions 510f that provide rounded
transitions between the first and second sides 510c, 510d. As the
cable 502 is passing from one side 510c, 510b of one separator 510
to the other side 500c, 510d of the adjacent separator 510, the
rounded portions 510f help to ensure that the cable is gently
guided along the pathway and is not exposed to any sharp edges. In
one aspect, the separators 510 are hollow or partially hollow at
the first end 510a in order to form the sloped portions 510e and
the rounded portions 510f However, the winding separator 510 can be
provided as an entirely solid structure without departing from the
concepts presented herein.
[0128] As shown, the base portion 516 of each winding separator 510
can be defined as having a top side 516a and a bottom side 516b
extending between opposite sides 516c,d and between opposite sides
516e,f. In the example shown, the base portion 516 is provided with
a generally rectangular shape, although other shapes are possible.
During the winding process, the base portion 516 enables a greater
amount of cable 502 to be wound into a coil 500 in comparison to a
winding separator 510 not having a base portion 516. The top side
516a of the base portion 516 provides a positive surface against
which the cable 502 can be wound and retained thereby allowing
cable 502 to be wound all the way to the second end 510b of the
winding separator. Where no base portion 516 is provided, the
winding process must be stopped at a point such that at least a
portion of the second end 510b of the winding separators 510
remains exposed such that the cable 502 cannot unintentionally
unwind beyond the separator 510.
[0129] The base portion 516 also provides a mounting location for
the wound coil 500 to be mounted within the housing 600. As stated
previously, the housing 600 is provided with a plurality of channel
members 616 at the sidewall 602. In one configuration, the each of
the channel members 616 extends between a first end 616a adjacent
the bottom wall 612 towards a second end 616b adjacent the top wall
610. In one aspect, the second end 616b is recessed from the top
edge 602a of the sidewall 602 to accommodate the thickness of the
top wall 610. The channel members 616 may be each provided with a
first side member 616c and a second side member 616d that extend
between the first and second ends 616a, 616b. Together, the side
members 616c, d and the sidewall 602 define a channel that receives
and retains the base portion 516 of a winding separator 510. As
configured, the wound coil 500 can be formed on a winding apparatus
and then mounted within the housing 600 by aligning and then
sliding the base members 516 of each winding separator 510 into the
corresponding channel member 616. Although the use of base members
516 and channel members 616 are a useful configuration for
providing a connection between the wound coil 500 and the housing
600, it should be appreciated that other cooperating structures may
be used without departing from the concepts described herein.
[0130] A payout tube 512, which also functions as a winding
separator, is also provided in the packaged cable dispenser 102
shown in FIGS. 9-22. In some examples, the cable outlet 112 of the
cable dispenser 102 is configured as, or includes, the payout tube
512. In one aspect, the payout tube 512 has a first end 512a, a
second end 512b, a first side 512c, and a second side 512d. The
payout tube 512 can also be configured with a stem portion 518, a
head portion 520, side flanges 522 and buttresses 524. In the
example shown, the payout tube is a single molded component. In
combination, the head portion 520 and the stem portion 518 define
the hollow interior 512e through which the cable 502 can extend
from the interior of the wound coil 500 to the exterior of the
housing 600. As shown, the side flanges 522 are provided to define
the first and second sides 512c, 512d and enable the payout tube
512 to function as a winding separator in the same manner as the
winding separators 510. The side flanges 522 are also provided with
sloped regions 522a that gently slope to the head portion 520 and
allow a segment of unwinding cable 502 to be guided up to the head
portion 520 without excessive bending or catching of the cable 502
on the head portion 520. As shown, the buttresses 524 extend from
the side flanges and the stem portion 518 on the first and second
sides 512c, 512d towards the head portion 520. In one aspect, the
buttresses 524 provide a transition from the sides 512c, 512d and
stem portion 518 to gently guide the cable 502 up to the head
portion 520 while also preventing the cable 502 from becoming hung
up or caught on the head portion 520.
[0131] The head portion 520 is also shaped to prevent the cable 502
from becoming bent too sharply or kinked as the cable 502 is being
pulled through the payout tube 512 and passing by one side 512c,
512d of the payout tube 512. The head portion 520 can be described
as having a rounded outer surface 520c for guiding the cable 502
about the payout tube 512 as the cable 502 passes by the payout
tube 512. The head portion 520 can also be described as having a
funneling surface 520d that smoothly guides the cable into the
hollow interior 512e. In one example, the head portion 520 is
provided as a toroidal shape having two axes of symmetry. For
example, and as most easily viewed at FIG. 32, the head portion 520
is symmetrical about an axis X and symmetrical about an axis Y. In
one aspect, the head portion 520 is elongated along the X axis
relative to the Y axis to create a rounded diamond-shape with a
leading edge 520a and a trailing edge 520b. The rounded leading
edge 520a aids in guiding the cable 502 to the appropriate side
512c, 512d of the payout tube 512 as the cable 502 is unwinding off
of the winding adjacent winding separators 510 which prevents
kinking or tangling of the cable 502. The outer surface 520c and
the funneling surface 520d also function as a bend radius limiter
for the cable 502. In one aspect, the outer surface 520c and
funneling surface 520d can be configured to define a radius of
about 1/4 inch to about 1/2 inch.
[0132] In one aspect, the payout tube 512 can be secured to the
housing with a clip member 530 that inserts into a corresponding
receptacle 630 provided at a notch 632 in the sidewall 602. As
shown, the clip member 530 is formed as a plate having an aperture
532 having a profile that matches at least a portion of the payout
tube 512. In the example shown, the aperture 532 is shaped to allow
the stem portion 518 and the side flanges 522 to be inserted
through the clip member 530. As shown, the clip member 530 is
formed as a separate component that can be mounted and secured onto
the payout tube 512 either before or after the cable 502 has been
wound to form the wound coil 500. Alternatively, the clip member
530 can be formed integrally with the rest of the payout tube 512.
As the payout tube 512 is slidable relative to the clip member 530,
the position of the payout tube 512 can be adjustable relative to
the housing 600 to optimize the location of the head portion 520
with respect to the interior of the wound coil 500. Such
adjustability would allow for the same constituent parts to be used
in multiple applications where differing cable dimensions and
properties and/or wound coil diameters may be associated with
different optimal locations for the head portion 520 within the
housing 600. In one embodiment, index positions can be provided on
the clip member 530 and/or the payout tube 512 such that the
desired position of the payout tube with respect to the housing 600
can be readily achieved during assembly. This general construction
is also advantageous in that different payout tubes 512 having
different lengths and head styles may be used with the same housing
600.
[0133] Referring to FIGS. 33-41, depictions of a cable 502 being
dispensed from a dispenser 102 having a clear package 600 at
different stages are shown in which the above described features of
the winding separators 510 and payout tube 512 are illustrated. In
FIG. 28, the cable 502 has just been unwound past the payout tube
512 second side 512d and is maintained on the first side 510c of
the adjacent winding separator 510-1 by the flared first end 510a
of the winding separator 510-1. FIG. 34 shows the cable 502 having
been pulled further through the payout tube 512 such that the cable
502 has lifted off of the winding separator 510-1 but is still
retained on the second side 510d of the next winding separator
510-2 by the flared first end 510a. Similarly, FIG. 35 shows the
cable 502 now having been lifted off of the winding separator 510-2
while still being maintained on the first side 510c of the adjacent
winding separator 510-3 by the flared first end 510a of the winding
separator 510-3. FIG. 68 shows the cable 502 having been pulled
further through the payout tube 512 such that the cable 502 has
lifted off of the winding separator 510-3 but is still retained on
the second side 510d of the next winding separator 510-4 by the
flared first end 510a.
[0134] Unlike the winding separators 510, the cable 502 is
simultaneously drawn through and past the payout tube 512 which
necessitates that the cable 502 flips over from one plane one side
of the payout tube 512 to another plane on the other side of the
payout tube 512. FIG. 37 shows the cable 502 at the beginning of
this process wherein the cable has lifted from the winding
separator 510-3 with the flared end 510e of the separator 510-3
having kicked the cable 502 out of plane such that the cable 502
can be transferred over from the second side 510d of separator
510-4 to the first side 512c of the payout tube 512. At the same
time, the rounded leading edge 520a of the payout tube head portion
520 is ensuring that the cable 502 continues to flip over to the
first side 512c as the cable draws nearer the payout tube 512.
FIGS. 38-40 show the cable 502 as it traces around the outer
portion 520c of the head portion and along the first side 520c of
the payout tube 512 until the cable 502 finally flips over and is
again engaged by the winding separator 510-1, but this time on the
second side 510d. The unwinding process continues in the same
manner for the next loop of cable 502 pulled through the payout
tube 512, but on opposite sides of the winding separators 510 and
the payout tube 512.
[0135] As described herein, the present disclosure provides a
system and method for inserting a telecommunications cable into a
slotted conduit. The conduit has a slot extending along a length of
the conduit. The system includes a non-rotating cable dispenser
configured to store a length of communications cable and dispense
the cable without need of rotating any element. The system further
includes a plow-like insertion device configured to guide the
communications cable from the cable dispenser to the conduit
through the slot of the conduit. The non-rotating cable dispenser
and the plow-like insertion device are described above.
[0136] In one example, the conduit can be pre-installed along a
desired path within a building or any installation location, such
as multi-dwelling units (MDUs). Then, the system of the present
disclosure including the non-rotating cable dispenser and the
insertion device can be moved along the pre-installed conduit to
plow the cable stored in the dispenser into the conduit. In another
example, the system including the non-rotating cable dispenser and
the insertion device can be mounted at a fixed location, and the
conduit can be pulled or otherwise moved relative to the system
such that the cable is pulled from the dispenser and loaded into
the conduit as the conduit moves past the system (i.e., the cable
dispenser and the insertion tool).
[0137] Referring now to FIGS. 42-53, example cabling systems and
methods are described and illustrated.
[0138] Referring to FIG. 42, a cabling system 1100 is described in
accordance with an exemplary embodiment of the present disclosure.
The cabling system 1100 includes a cable assembly 1102, which is
disaggregated into a jacket portion 1104 and a fiber optic cable
portion 1106. As described herein, the jacket portion 1104 and the
fiber optic cable portion 1106 are separately provided and
aggregated into the cable assembly 1102 in field.
[0139] Referring to FIG. 43, the jacket portion 1104 of the cable
assembly 1102 is configured to provide a robust outer jacket for
the fiber optic cable portion 1106. The jacket portion 1104 is
designed to be installed in field (i.e., a field installable
jacket). The jacket portion 1104 includes an outer protective layer
or jacket 1110 that defines a passage 1112 for receiving the fiber
optic cable portion 1106.
[0140] In some examples, the outer jacket 1110 includes one or more
strength members 1114 embedded in a wall of the jacket 1110. The
strength members 1114 can be made of various materials. For
example, the strength members 1114 include relatively rigid rods,
such as fiberglass-reinforced polymer rods, metal rods, or like
structures. The strength members 1114 can have sufficient stiffness
to prevent excessive bending of the outer jacket 1110 and thus
maintain the bend radius requirement of the fiber optic cable
portion 1106 received within the jacket portion 1104. The strength
member 1114 can also have sufficient column strength to allow the
outer jacket 1110 to be pushed or pulled along a routing path 1180
(FIG. 4) during installation. In addition or alternatively, the
strength member 1114 includes more flexible elements, such as yarns
or tapes (e.g., Aramid yarns or tapes).
[0141] In some examples, the jacket portion 1104 includes a
longitudinal slit 1116 configured to permit the outer jacket 1110
to be opened along its length and receive the fiber optic cable
portion 1106 into the passage 1112 as the fiber optic cable portion
1106 is laterally loaded through the slit 1116. The longitudinal
slit 1116 can have various configurations, such as seam, slot,
opening, and any suitable structures. As described below, the
longitudinal slit 1116 can be closed in various ways. For example,
the fiber optic cable portion 1106 can be laterally inserted into
the jacket portion 1104 and zipped in to accommodate the fiber
optic cable portion 1106 within the jacket portion 1104. In other
examples, the fiber optic cable portion 1106 can be plowed into the
jacket portion 1104. In yet other examples, other methods can be
used to insert the fiber optic cable portion 1106 into the jacket
portion 1104. Such insertion of the fiber optic cable portion into
the jacket portion can be manually performed with or without a
tool, or automatically conducted with an automated tool.
[0142] In some examples, the jacket portion 1104 includes an
interlocking longitudinal interface 1118 configured to provide a
mechanical interlock that retains the longitudinal slit 1116 in a
closed configuration after the fiber optic cable 1106 has been
loaded within the outer jacket 1110.
[0143] The jacket portion 1104 has a maximum cross sectional
diameter D1 that is larger than a maximum cross sectional diameter
D2, D2' of the fiber optic cable portion 1106 (FIGS. 44 and 45). In
one example, the maximum diameter D1 of the jacket portion 1104 is
about 2 to 5 times as large as the maximum diameter D2, D2' of the
fiber optic cable portion 1106. In other examples, the maximum
diameter D1 of the jacket portion 1104 is about more than 5 times
as large as the maximum diameter D2, D2' of the fiber optic cable
portion 1106.
[0144] In some examples, the fiber optic cable portion 1106 is
configured to be more flexible and lightweight than the jacket
portion 1104. In one example, the fiber optic cable portion 1106 is
about 2 to 5 times more flexible than the jacket portion 1104. In
other examples, the fiber optic cable portion 1106 is about more
than 5 times more flexible than the jacket portion 1104.
[0145] Referring to FIGS. 44 and 45, the fiber optic cable portion
1106 includes a manageable fiber optic cable that is smaller, more
flexible, and more lightweight than the jacket portion 1104. As
illustrated in FIG. 44, in some examples, the fiber optic cable
portion 1106 is merely a coated optical fiber 1107. For example,
the fiber optic cable portion 1106 includes a core 1120, a cladding
layer 1122, and a coating layer 1124. The coating layer 1124 can
include at least one polymeric coating, such as acrylate or other
polymer. In other examples, the coating layer 1124 includes a
plurality of protective layers, such as an initial coating layer
(e.g., acrylate) covered by an outer buffer layer.
[0146] In some examples, the fiber optic cable portion 1106 is a
micro-cable.
[0147] As illustrated in FIG. 45, in some examples, the fiber optic
cable portion 1106 includes a tensile strength structure 1126 and a
cable jacket 1128, as well as an optical fiber 1107 including the
core 1120, the cladding layer 1122, and the coating layer 1124. The
tensile strength structure 1126 can include one or more strength
members or layers. The tensile strength structure 1126 can be
positioned between the optical fiber 1107 and the cable jacket 1128
of the manageable fiber optic cable.
[0148] The tensile strength structure 1126 can be configured to
provide tensile strength without providing meaningful compressive
strength. The tensile strength structure 1126 can be highly
flexible to allow the manageable fiber optic cable 1106 to be bent
along a relatively tight radius to enhance the ability to store the
manageable fiber optic cable 1106 in a small volume or package.
[0149] In some examples, the tensile strength structure 1126 can
include a yarn or yarn-like strength element (e.g., Aramid yarn) or
a tape or tape-like strength element. In some examples, the
manageable fiber optic cable 1106 has a minimum bend radius less
than 100 mm. In other examples, the manageable fiber optic cable
has a minimum bend radius of around 2-5 mm. In certain examples,
the manageable fiber optic cable 1106 has a maximum cross-dimension
or outer diameter D2, D2' of between about 4 and about 1
millimeters.
[0150] As shown in FIGS. 42 and 46, in some examples, at least one
of opposite ends of the manageable fiber optic cable 1106 can be
pre-connectorized prior to installation of the cabling system in
the field. For example, connectors 1130 can be installed to the
ends of the fiber optic cable 1106 at the factory or in a
controlled manufacturing setting.
[0151] The manageable fiber optic cable 1106 can be managed
separately from the outer jacket portion 1104 before, during,
and/or after installation. In some examples, a storage device 1150
is used to store the fiber optic cable 1106, as illustrated in
FIGS. 42 and 46. The storage device 1150 is configured to store the
manageable fiber optic cable 1106 in a relatively small volume and
allow the manageable fiber optic cable to be readily paid out from
the storage device during deployment of the cabling system. In this
document, therefore, the storage device 1150 is also referred to as
a cable dispenser.
[0152] The storage device 1150 can have various configurations. In
some examples, the storage device 1150 includes a rotatable spool
that rotates as the manageable fiber optic cable is paid out.
Examples of the rotatable spool are described in U.S. Pat. No.
7,715,679, titled Fiber Optic Enclosure with External Cable Spool,
issued May 11, 2010, U.S. Pat. No. 7,756,379, titled Fiber Optic
Enclosure with Internal Cable Spool, issued Jul. 13, 2010, and U.S.
Pat. No. 7,869,682, titled Fiber Optic Enclosure with Tear-Away
Spool, issued Jan. 11, 2011, the disclosures of which are hereby
incorporated by reference in their entireties.
[0153] In other examples, the storage device 1150 includes a
containment device that allows the manageable fiber optic cable to
be paid out without rotation of the containment device. Examples of
such a non-rotating containment device are described in U.S. Patent
Application Publication No. 2016/0207723, titled Coreless Wound
Coil Dispenser with Optional Cable Storage for an Optical Terminal
Network, filed Dec. 18, 2015, the entirety of which is hereby
incorporated by reference.
[0154] In yet other examples, other types of the storage device
1150 are also possible. For example, the storage device 1150 does
not include a rotatable or non-rotatable spool or reel around which
the fiber optic cable portion 1106 is wrapped. The fiber optic
cable portion 1106 can be contained in the storage device 1150
without support.
[0155] Referring now to FIG. 46, an example method for installing a
fiber optic cable using the cabling system 1100 is described. In
some examples, the outer jacket portion 1104 and the fiber optic
cable portion 1106 are delivered in disaggregated state to an
installation site in the field. For example, the outer jacketing
portion 1104 can be delivered as being coiled about a relatively
large spool 1160 and the manageable fiber optic cable portion 1106
can be delivered within or on a separate management device, such as
the storage device 1150.
[0156] During installation, the manageable fiber optic cable
portion 1106 is loaded laterally into the outer jacket portion 1104
to provide an aggregated portion 1170 of the cable assembly 1102.
In some examples, the fiber optic cable portion 1106 is inserted
into the jacket portion 1104 through the longitudinal slit
1116.
[0157] By aggregating the outer jacket portion 1104 and the
manageable fiber optic cable portion 1106, the fiber optic cable
portion 1106 can be protected by the robust nature of the outer
jacket portion 1104 during installation and/or routing. The jacket
portion 1104 can also be used to effectively push or pull the
aggregated cable assembly 1102 along a desired routing path 1180.
Examples of the routing path 1180 include conduits, sleeves, tubes,
ducts, risers, plenums, or any other routing passages between
various places, such as a location between a distribution pedestal
and a subscriber location, a place on a cell tower, a place inside
a building, an underground location, a location along wires, and
any other interior or exterior locations.
[0158] Once the aggregated portion 1170 of the cable assembly 1102
has been installed along the desired routing path 1180, the outer
jacket portion 1104 can be cut to length. In this way, the length
of the outer jacket portion 1104 can be customized in the field so
that excess length of the outer jacket portion 1104 need not be
managed and stored.
[0159] After installation, the manageable fiber optic cable portion
1106 can extend beyond the ends of the outer jacket portion 1104.
The flexible and small nature of the manageable fiber optic cable
portion 1106 allows it to be efficiently and effectively managed
and stored. The length of the manageable fiber optic cable portion
1106 need not be customized. Instead, the manageable fiber optic
cable portion 1106 can be pre-connectorized with a standard length
longer than the length of the intended installation path, and the
excess length of the manageable fiber optic cable portion 1106 can
be efficiently stored by a management device having a relatively
small volume. Such a management device includes the storage device
1150 and a fiber optic enclosure in the field.
[0160] In some examples, the cabling system 1100 includes a tool
1190 for facilitating the insertion of the fiber optic cable
portion 1106 into the jacket portion104. The tool 1190 can have
various configurations. One example of the tool 1190 includes the
jacket insertion device 108 as described and illustrated herein.
Other examples of the tool 1190 are described below.
[0161] Referring to FIGS. 47-50, another example of the jacket
portion is described. In this example, the jacket portion is
generally designated as reference 1200. Similarly to the jacket
1104 above, the jacket 1200 is configured to receive a cable
therein once the jacket and the cable are carried to a field
location.
[0162] The jacket 1200 is configured to define an interior passage
1202 for receiving a cable 1106, as shown in FIG. 49. As shown in a
cross-sectional view of FIG. 48, the jacket 1200 is formed as a
split sleeve 1204 having a flexible section 1206 and mating edges
1208, 1210 of the flexible section 1206. In some embodiments, the
jacket 1200 is manufactured by extrusion. The jacket 1200 is
snapped around the cable 1106 by mating a first edge 1208 with a
second edge 1210.
[0163] The jacket 1200 includes the flexible section 1206 before
wrapping a cable. Since the jacket 1200 remains flat as extruded,
the jacket 1200 can be wound on a large bulk roll for
transportation to a field location. Once carried to a field
location, the flat sleeve 1204 is rolled out (or paid out from a
roller, reel, or spool), and is wrapped around a cable.
[0164] In some examples, the jacket 1200 includes a stiffening
element 1212 configured to provide a longitudinal strength to an
assembled cable product (i.e., the jacket including the cable). The
stiffening element 1212 makes it easier to carry or push the
assembled cable product through conduits, tubes, ducts, risers,
plenums, or any other routing passages. In the illustrated example,
the stiffening element 1212 is shaped as a rod and provided at the
second edge 1210. Other locations are also possible in other
examples. The stiffening element 1212 is made of various materials.
One example material is fiberglass or other fiber-reinforced
plastic. Another example material is metal.
[0165] The jacket 1200 includes a clamp device 1214 to mate the
first edge 1208 and the second edge 1210 together. In some
examples, the clamp device 1214 includes a pushing edge 1216 formed
at the first edge 1208 and a receiving edge 1218 formed at the
second edge 1210. The receiving edge 1218 defines a socket 1220 by
cooperating with a portion containing the stiffening element 1212
at the second edge 1210. The socket 1220 is configured to receive
and hold the pushing edge 1216 therein. In some examples, the
pushing edge 1216 and/or the receiving edge 1218 include hook
elements 1222, 1224 that engage each other to mate the pushing edge
1216 and the receiving edge 1218 together. In some examples, at
least one of the pushing edge 1216 and the receiving edge 1218 is
made to be flexible or deflectable for improved mating.
[0166] In some examples, the pushing edge 1216 and the receiving
edge 1218 can be sealed with adhesives (e.g., gel). In other
examples, the pushing edge 1216 and the receiving edge 1218 are
just mechanically mated.
[0167] As shown in FIG. 49, the jacket 1200 is dimensioned to
lightly squeeze the cable radially when a cable 1106 is placed in
the interior passage 1202 of the jacket 1200. Accordingly, the
cable 1106 is prevented from sliding along the length of the jacket
1200. In some examples, the jacket 1200 includes a cable holding
element 1226 configured to abut with the cable 1106 when the jacket
1200 wraps around the cable 1106. In the illustrated example, the
cable holding element 1226 is formed at the receiving edge 1218
opposite to the hook element 1224. The cable holding element 1226
is configured to be flexible to accommodate different sizes of
cable 1106 received in the jacket. The cable holding element 1226
operates to grip the cable as the cable is plowed into the jacket,
and prevent or limit the amount of free translation of the cable
longitudinally within the jacket. This configuration reduces a risk
to pull on one end of the cable and cause it to telescope out of
the entire jacket, thereby possibly damaging the arrangement at the
other end.
[0168] In other examples, the jacket includes a fixation device
that holds or retains the manageable fiber optical cable relative
to the outer jacket as the manageable fiber optic cable is plowed
into the outer jacket. In this way, the cable cannot slide axially
or longitudinally relative to the jacket during the insertion
process. In some examples, the rollers (e.g., a tool 1230 below)
can be used to achieve this feature. For example, the rollers can
pinch the jacket hard enough to clamp the manageable fiber optic
cable to prevent it from sliding.
[0169] Referring to FIG. 50, a tool 1230 can be used to zip the
jacket 1200 around a cable 1106. Once a cable 1106 is fed on the
split sleeve 1204 (e.g., on or above the flexible section 1206
between the mating edges 1208, 1210), at least one of the pushing
edge 1216 and the receiving edge 1218 is grabbed and moved close to
each other. The tool 1230 is used to snaps the pushing edge 1216
into the socket 1220 of the receiving edge 1218 so that the pushing
edge 1216 and the receiving edge 1218 are held together.
[0170] In some examples, the tool 1230 includes a pair of rollers
1232, 1234 (also referred to herein as pinch rollers) that are
spaced apart to define a passage through which the jacket 1200
passes. The rollers 1232, 1234 rotates in the opposite directions
and squeezes the jacket 1200 therebetween such that the pushing
edge 1216 is mated with the receiving edge 1218 (e.g., the socket
1220 thereof). The motion of the rollers 1232, 1234 that roll to
pinch the jacket 1200 can also propel the zipped jacket forward to
a desired location (for example, through another larger conduit).
In other examples, other types of tool can be used to zip the
jacket with a cable therein. The tool 1230 can be manually
operated. In other examples, the tool 1230 can be electronically
operated.
[0171] Referring to FIGS. 51 and 52, yet another example of the
jacket portion is described. In this example, the jacket is
generally designed as reference 1300. Similarly to the jackets 1104
and 1200 above, the jacket 1300 is configured to receive a cable
1106 therein once the jacket and the cable are carried to a field
location.
[0172] Similarly to the jacket 1200, the jacket 1300 is configured
to define an interior passage 1302 for receiving a cable 1106, as
shown in FIG. 52. The jacket 1200 is formed as a split sleeve 1304
having a flexible section 1306 and mating edges 1308, 1310. In some
embodiments, the jacket 1300 is manufactured by extrusion. The
jacket 1300 is snapped around the cable 1106 by mating a first edge
1308 with a second edge 1310.
[0173] The jacket 1300 includes the flexible section 1306 before
wrapping a cable. Since the jacket 1300 remains flat as extruded,
the jacket 1300 can be wound on a large bulk roll for
transportation to a field location. Once carried to a field
location, the flat sleeve 1304 is rolled out (or paid out from a
roller, reel, or spool), and is wrapped around a cable.
[0174] In some examples, the jacket 1300 includes a stiffening
element 1312 configured to provide a longitudinal strength to an
assembled cable product (i.e., the jacket including the cable). The
stiffening element 1312 makes it easier to carry or push the
assembled cable product through a conduit, tube, or any other
routing passage. In the illustrated example, the stiffening element
1312 is provided at the first edge 1308. Other locations are also
possible in other examples. The stiffening element 1312 is made of
various materials. One example material is fiberglass or other
fiber-reinforced plastic. Another example material is metal.
[0175] The jacket 1300 includes a clamp device 1314 to mate the
first edge 1308 and the second edge 1310 together. In some
examples, the clamp device 1314 includes a pushing edge 1316 formed
at the first edge 1308 and a receiving edge 1318 formed at the
second edge 1310. The receiving edge 1318 defines a socket 1320
that is open though a longitudinal slit 1320. The socket 1320 is
configured to receive the pushing edge 1316 through the slit 1320
and hold the pushing edge 1316 therein. In some examples, the
receiving edge 1318 is made to be flexed open as the pushing edge
1316 is inserted into the socket 1320. As such, the pushing edge
1316 and the receiving edge 1318 are zipped together, just as a
continuous ziplock, to enclose a cable therein.
[0176] In this example, the stiffening element 1312 is used to
reinforce the pushing edge 1316 so that the pushing edge 1316 is
effectively engaged with the receiving edge 1318. Further, as
described with respect to the jacket 1200, the edges 1316 and 1318
are combined with a cable therein as the jacket 1300 (e.g., the
split sleeve 1304) is pushed toward a desired destination, or
through a larger conduit. The jacket 1200 can be zipped either
manually, or by a tool which can be either manually or
electronically operated. Such a tool can be similar to the tool
1230 as described above.
[0177] In some examples, the pushing edge 1316 and the receiving
edge 1318 can be sealed with adhesives (e.g., gel). In other
examples, the pushing edge 1316 and the receiving edge 1320 are
just mechanically mated. In some examples, the receiving edge 1318
(with the pushing edge 1316) abuts with the cable received in the
jacket, and slightly exerts pressure against the cable. This
configuration functions similarly to the cable holding element 1226
above.
[0178] With this configuration, the jacket 1104, 1200, 1300
provides a structure for easily inserting a cable 1106 therein over
a longer distance in a field location where the cable 1106 is
installed and/or routed. The field location can be various places,
such as a location between a distribution pedestal and a subscriber
location, a place on a cell tower, a place inside a building, an
underground location, a location along wires, and any other
interior or exterior locations.
[0179] The clamping feature of the jacket, such as the pushing and
receiving edges, allows a significantly long length of the jacket
to be zipped without accumulating tension on the cable. The cable
is clamped within the jacket (or the split sleeve) as it is
assembled with a cable, and a longitudinal slippage between the
cable and the jacket (or the split sleeve) is reduced. Therefore,
no significant tension can accumulate. The jacket of the present
disclosure provides improved ability to push a cable for a longer
distance while retaining sufficient flexibility to go around bends
in a piping system into which the jacket with the cable is
pushed.
[0180] In some examples, the jacket is configured such that the
cable inserted within the jacket has a slight serpentine shape as
the cable is contained inside the jacket. Over long distances, the
serpentine shape of the cable allows the cable to elongate without
being tensioned if the jacket is stretched. For example, the jacket
includes structures that cause the cable to have a serpentine shape
when the cable is placed within the jacket.
[0181] For example, in FIG. 49, the cable holding element 1226 can
be extruded such that it is wavy along the longitudinal axis. In
yet other examples, the cable holding element 1226 can be formed
intermittently along the longitudinal axis. For example, the cable
holding element 1226 is alternatingly present in a pattern along
the longitudinal axis. By way of example, the cable holding element
1226 is present for certain length (e.g., a few inches) and then
not present for certain length (e.g., a few inches) along the
longitudinal axis, and this pattern is repeated along the entire
length of the jacket 1200. Such a wavy or intermittent profile of
the cable holding element 1226 can induce a serpentine shape in the
fiber once the fiber is inserted in the jacket. Further, the wavy
or intermittent shape of the cable holding element 1226 can provide
a light axial grip.
[0182] In other examples, a serpentine shape can be formed by
extruding the entire profile of a jacket such that the jacket is
slightly serpentine as it is extruded. As such, the entire
structure of the jacket has ability to expand without tensioning
the fiber portion.
[0183] In some examples, such serpentine structures in the jacket
permit the manageable fiber optic cable to define a sinusoidal
wave-like shape or path within the outer jacket. This provides
excess manageable cable length within the outer jacket so that if
the jacket is stretched axially/longitudinally, the excess cable
length will be taken up (i.e., the manageable fiber optic cable
will straighten within the outer jacket). Without the excess cable
length, the cable may break or be damaged when the outer jacket is
stretched.
[0184] As described herein, the jacket can be made of various
materials, such as a soft plastic-like polyethylene over a pre-made
fiberglass rod. By way of example, the cable 1106 has a diameter of
about 1 mm. In some examples, the fiberglass rod 1212 has a
diameter similar to the diameter of the cable. In other example,
the fiber glass rod can have different sizes to create the jacket
of different stiffness for different applications.
[0185] As described herein, the split tube jacket 1104, 1200, 1300
is used to conveniently install different lengths of cable at
various locations. Referring to FIG. 53, a method 1318 is described
for installing a fiber optic cable in field. In some examples, a
fiber optic cable 1106 and a field-installable jacket 1104, 1200,
1300 are provided at a field location (operation 1402). Then, the
cable can be inserted or placed into the interior passage of the
field-installable jacket (operation 1404). For example, the cable
can be wrapped by the jacket. In some examples, the cable is fed to
the jacket as the jacket is deployed along a desired path. The
assembly of the cable and the jacket can be either pushed or pulled
along the path as the cable is inserted into the jacket.
[0186] Once the cable is placed inside the jacket, the
field-installable jacket is closed such that the interior passage
encloses the cable (operation 1406). As described herein, in some
examples, a tool can be used to close the jacket. In other
examples, the jacket is closed manually. The jacket can be cut to a
length as desired in the field (operation 1408). A remaining length
of the cable can be stored in a desired place, such as an fiber
optic enclosure (operation 1410).
[0187] In other examples, the cable can be placed inside the jacket
before delivered to a field location.
[0188] In some examples, the split tube jacket 1104, 1200, 1300
(i.e., the split sleeve thereof) is pre-loaded with a
water-blocking gel therein. For example, a water-blocking gel can
be loaded into the split tube jacket 1104, 1200, 1300 prior to
coiling the split tube jacket 1104, 1200, 1300 on a spool during a
manufacturing stage (e.g., at the factory). The pre-loading
water-blocking gel can help to make the split tube jacket 1104,
1200, 1300 resistant to water intrusion once the split sleeve has
been zipped closed. In this way, the system may be used for outdoor
fiber installations. In some examples, a small size would be ideal
for outdoor underground applications. For example, once a
pre-ferrulized optical fiber has been loaded into the
gel-containing jacket 1104, 1200, 1300 and the jacket 1104, 1200,
1300 (i.e., the split sleeve thereof) has been zipped shut, the
jacket 1104, 1200, 1300 can be installed in a micro-trench.
[0189] As such, the cabling system of the present disclosure
provides a telecommunications cable and a jacket separately. The
cable can be inserted into the jacket once they are delivered to
the field. In some examples, the system includes a jacket having
structures for easily inserting a cable therein over a long
distance in a field location. The system can further include a tool
for facilitating the insertion of the cable into the jacket. In
certain examples, the jacket is extruded as a flexible sleeve or
section having a clamping structure. The clamping feature can be
provided at a pushing edge and a receiving edge of the flexible
section. Since the jacket is flat as extruded in the form of
flexible sleeve, the jacket (as the flexible sleeve) can be wound
on a large bulk roll for easy storage and transportation to a field
location. Once carried to a field location, the flexible sleeve can
be rolled out and is wrapped around a cable. In certain examples, a
remaining cable that is not assembled with the jacket can be stored
in a desired place, such as within a storage device or an
enclosure. In certain examples, a stiffening element is provided to
either or both of the pushing edge and the receiving edge. The
stiffening element can improve ability to push the jacketed cable
for a longer distance while retaining sufficient flexibility to go
around bends in a piping system into which the jacket with the
cable is pushed or pulled.
[0190] As described herein, a telecommunications cable, such as a
fiber optic cable, is deaggregated from a jacket, and the cable and
the jacket are combined or merged in a field location where the
cable is to be routed. In some examples, the cable is fed into the
jacket as the jacket is deployed along a predetermined path.
[0191] As a telecommunication cable, such as a fiber optic cable,
is delicate, the cable needs to be protected by a jacket or a
protective outer layer. A jacket is used to receive and protect the
cable along a desired path. In accordance with the present
disclosure, a cable and a jacket is separately provided in a field
location. As cables are relatively small in size (e.g., a cross
sectional diameter), the cables can be stored in a small package
and carried to field in the package. For example, cables can be
stored in a dispenser (either rotating or non-rotating) or any
other storage and dispensing device, such as a coil, reel, roller,
or spool) and carried to field. In certain examples, different
lengths of cables are prepared as different packages such that a
technician or installer can select and use a package containing a
desired length of cable. In certain examples, the cables are
preconnectorized at either or both of the ends thereof.
[0192] The jacket in accordance with the present disclosure has
structures for easily inserting a cable therein over a long
distance in a field location. Further, the jacket is configured to
be easily stored and carried to field, separately from a cable. In
the field, the jacket can be fed with a cable as the jacket is
deployed to a predetermined path. Once the cable is routed as
desired, the jacket can be cut to length and any remaining length
of the cable can be stored in place, such as a storage device or an
enclosure. Since the jacket can be cut to length after a desired
length of cable is routed, a technician or installer does not need
to know the exact length of cable to be routed along the path.
[0193] In certain examples, the system can further include a tool
for facilitating the insertion of the cable into the jacket. The
tool is configured to feed a cable into a jacket as the jacket is
routed along a path by either pulling or pushing an assembly of the
cable and the jacket.
[0194] In certain examples, the jacket is extruded as a flexible
sleeve or section having a clamping structure. The clamping feature
can be provided at a pushing edge and a receiving edge of the
flexible section. Since the jacket is flat as extruded in the form
of flexible sleeve, the jacket (as the flexible sleeve) can be
wound on a large bulk roll for easy storage and transportation to a
field location. Once carried to a field location, the flexible
sleeve can be rolled out and is wrapped around a cable. In certain
examples, a remaining cable that is not assembled with the jacket
can be stored in a desired place, such as within an enclosure.
[0195] The clamping feature of the jacket may allow a significantly
long length of the jacket to be zipped without accumulating tension
on the cable. As a cable is laterally inserted into the jacket or
wrapped around by the jacket, a longitudinal slippage between the
cable and the jacket may be significantly reduced.
[0196] In certain examples, a stiffening element is provided to
either or both of the pushing edge and the receiving edge. The
stiffening element can improve ability to push the jacketed cable
for a longer distance while retaining sufficient flexibility to go
around bends in a piping system into which the jacket with the
cable is pushed.
[0197] In one aspect, a method for installing a cable includes
providing a cable and a field-installable jacket to a field
location. The field-installable jacket is configured to define an
interior passage and has an opening for receiving the cable into
the interior passage. The opening is defined along a length of the
field-installable jacket. The method further includes placing the
cable to the interior passage of the field-installable jacket,
closing the opening of the field-installable jacket to form the
interior passage enclosing the cable, and cutting the
field-installable jacket into a desired length. In addition, the
method may further include storing a remaining length of the cable
in an enclosure.
[0198] In another aspect, a system for installing a cable includes
a cable and a field-installlable jacket configured to define an
interior passage for receiving the cable. The jacket has a pushing
edge, a receiving edge, and a flexible section extending between
the pushing edge and the receiving edge. The interior passage is
defined by engaging the pushing edge with the receiving edge. The
system may further include a stiffening element provided to at
least one of the pushing edge and the receiving edge.
[0199] The various examples and teachings described above are
provided by way of illustration only and should not be construed to
limit the scope of the present disclosure. Those skilled in the art
will readily recognize various modifications and changes that may
be made without following the examples and applications illustrated
and described herein, and without departing from the true spirit
and scope of the present disclosure.
* * * * *