Adaptive cable assembly and method of construction

Abstract

An adaptive cable assembly and a method of construction thereof are provided. The method includes multi-way fusion splicing of an optical fiber at the cable and an optical fiber at the connectorized fiber tail assembly, and positioning the multi-way fusion splice in a cavity extending along the longitudinal axis formed by a body extending along the longitudinal axis. The body forms a first open end along the longitudinal axis through which the connectorized fiber optic tail assembly extends when the multiplexed splice is positioned in the cavity. The body forms a second open end along the longitudinal axis through which the fiber optic cable extends when the multiplex splice is positioned in the cavity.

Description

[0001] Priority declaration

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 389,639, filed on July 15, 2022, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure relates generally to fiber optic cable assemblies and assembly processes, and more particularly to improved cable assemblies and assembly processes that support rapid and low labor final assembly of medium to high fiber count cable assemblies. Background Art

[0004] In the fiber optic and telecommunications industries, customers demand fast assembly and delivery of products at low price points. Additionally, they want to reduce shipping costs and carbon footprint.

[0005] Therefore, an improved fiber optic cable assembly and assembly process that would address one or more of the above-identified problems would be advantageous and desirable in the art. Summary of the invention

[0006] Embodiments, aspects, and advantages of the present invention according to the present disclosure will be partially described in the following description, or may be apparent from the description, or may be learned and understood through technical practice.

[0007] One aspect of the present disclosure relates to a method for constructing an adaptive cable assembly. The method includes performing a multi-way fusion splicing of optical fibers at a cable and optical fibers at a connectorized fiber tail assembly, and positioning the multi-way fusion splice in a cavity extending along the longitudinal axis formed by a body extending along the longitudinal axis. The body forms a first open end along the longitudinal axis, and when the multi-way fusion splice is positioned in the cavity, the connectorized fiber tail assembly extends through the first open end. The body forms a second open end along the longitudinal axis, and when the multi-way fusion splice is positioned in the cavity, the optical fiber cable extends through the second open end.

[0008] Another aspect of the present disclosure relates to a cable assembly, comprising a body extending along a longitudinal axis. The body forms a first open end and a second open end along the longitudinal axis. The first open end forms a generally rectangular cross-sectional area, and the second open end forms a generally circular cross-sectional area. The body forms a cavity extending along the longitudinal axis. An attachment interface is positioned at the second open end, the attachment interface forming a raised wall or clip, and the raised wall or clip is configured to receive a shield.

[0009] These and other features, aspects and advantages of the present invention will be better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the technology and, together with the description, serve to explain the principles of the technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] A full and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0011] Figure 1 A perspective view of an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0012] Figure 2 According to some aspects of the present disclosure, Figure 1 A perspective view of an embodiment of a main body of an adaptive cable assembly;

[0013] Figure 3 According to some aspects of the present disclosure, Figure 1 An exploded perspective view of components of an embodiment of an adaptive cable assembly;

[0014] Figure 4 According to some aspects of the present disclosure, Figure 1 A side cross-sectional view of an embodiment of an adaptive cable assembly;

[0015] Figure 5 A perspective view of an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0016] Figure 6 According to some aspects of the present disclosure, Figure 5 An exploded perspective view of an embodiment of an adaptive cable assembly;

[0017] Figure 7 According to some aspects of the present disclosure, Figure 5 A perspective view of an embodiment of a main body of an adaptive cable assembly;

[0018] Figure 8 According to some aspects of the present disclosure, Figure 5 A side cross-sectional view of an embodiment of an adaptive cable assembly;

[0019] Fig. 9 According to some aspects of the present disclosure, Figure 5 A side cross-sectional view of a first dimension of an embodiment of an adaptive cable assembly;

[0020] Fig.10 According to some aspects of the present disclosure, Figure 5A side cross-sectional view of a second dimension of an embodiment of an adaptive cable assembly;

[0021] Fig.11 A perspective view of an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0022] Fig.12 According to some aspects of the present disclosure, Fig.11 An exploded perspective view of an embodiment of an adaptive cable assembly;

[0023] Fig.13 According to some aspects of the present disclosure, Fig.11 A perspective view of an embodiment of a main body of an adaptive cable assembly;

[0024] Fig.14 According to some aspects of the present disclosure, Fig.11 A side cross-sectional view of a first dimension of an embodiment of an adaptive cable assembly;

[0025] Fig.15 According to some aspects of the present disclosure, Fig.11 A side cross-sectional view of a second dimension of an embodiment of an adaptive cable assembly;

[0026] Fig.16 A perspective view of an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0027] Fig.17 According to some aspects of the present disclosure, Fig.16 A perspective view of an embodiment of a main body of an adaptive cable assembly;

[0028] Fig.18 According to some aspects of the present disclosure, Fig.16 A side cross-sectional view of a first dimension of an embodiment of an adaptive cable assembly;

[0029] Fig.19 According to some aspects of the present disclosure, Fig.16 A side cross-sectional view of a second dimension of an embodiment of an adaptive cable assembly;

[0030] Fig. 20 A perspective view of an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0031] Fig.21 According to some aspects of the present disclosure, Fig. 20 An exploded perspective view of an embodiment of an adaptive cable assembly;

[0032] Fig. 22 According to some aspects of the present disclosure, Fig. 20 A perspective view of an embodiment of a main body of an adaptive cable assembly;

[0033] Fig.23 According to some aspects of the present disclosure, Fig. 20 A side cross-sectional view of an embodiment of an adaptive cable assembly;

[0034] Fig.24 A flow chart outlining exemplary steps of a method for constructing an adaptive cable assembly is provided;

[0035] Fig.25 A perspective view of an exemplary embodiment of a splicing device including an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0036] Fig.26 A plan view of an exemplary embodiment of a splicing device including an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0037] Fig. 27 A plan view of an exemplary embodiment of a splicing device including an embodiment of an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0038] Fig.28 An embodiment of steps of a method for constructing an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0039] Fig.29 An embodiment of steps of a method for constructing an adaptive cable assembly according to some aspects of the present disclosure is provided;

[0040] Fig.30 Embodiments of steps of a method for constructing an adaptive cable assembly according to some aspects of the present disclosure are provided.

[0041] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0042] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. The word "exemplary" is used herein to mean "used as an example, instance or illustration". Any embodiment described herein as "exemplary" is not necessarily to be interpreted as being preferred or advantageous over other embodiments. In addition, each example is provided in an explanatory manner, rather than a limitation on the technology. In fact, it is obvious to those skilled in the art that modifications and variations can be made in the present technology without departing from the scope or spirit of the claimed technology. For example, a feature illustrated or described as part of one embodiment can be used with another embodiment to produce yet another embodiment. Therefore, it is intended that the present disclosure covers such modifications and variations and their equivalents as falling within the scope of the appended claims. The detailed description uses numbers and letter marks to refer to features in the drawings. The same or similar marks in the drawings and descriptions are used to refer to the same or similar parts of the present invention.

[0043] As used herein, the terms "first", "second" and "third" may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of the various components. The singular forms "one", "an" and "the" include plural references unless the context clearly dictates otherwise. The terms "connect", "fix", "attach to" and the like refer to both direct connection, fixation or attachment and indirect connection, fixation or attachment through one or more intermediate components or features, unless otherwise specified herein. As used herein, the terms "include", "comprise", "have" or any other variation thereof are intended to cover non-exclusive inclusion. For example, a process, method, article or device including a list of features is not necessarily limited to those features, but may include other features that are not explicitly listed or inherent to such processes, methods, articles or devices. In addition, unless explicitly stated to the contrary, "or" refers to inclusive or, not exclusive or. For example, condition A or B is satisfied by any of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0044] Ranges provided herein include their endpoints. For example, a range of 1 to 100 includes 1 and 100.

[0045] Approximate terms such as "about," "generally," "approximately," or "substantially" include values ​​within ten percent full-scale error from the lowest value embodiment to the highest value embodiment. For example, an embodiment including a range from about 10 to about 100 with ten percent full-scale error may include values ​​from 1 to 109.

[0046] Benefits, other advantages, and solutions to problems are described below with respect to specific embodiments. However, benefits, advantages, solutions to problems, and any (one or more) features that may cause any benefit, advantage, or solution to occur or become more obvious should not be construed as key, required, or essential features of any or all claims.

[0047] Provided are embodiments of a cable assembly and a method for constructing or assembling a cable assembly. Embodiments provided herein can provide for rapid and low labor assembly of medium to high fiber count cable assemblies. Additionally or alternatively, embodiments provided herein can allow for mass production of components that can be stored and available on demand for constructing high fiber count or complex terminated cable assemblies on demand, in the field, at the point of installation, or to allow for repair and reconfiguration of existing cables.

[0048] Referring now to the drawings, embodiments of adaptive cable assemblies 100 are provided according to aspects of the present disclosure. The cable assembly 100 includes a body 110 extending along a longitudinal axis 11. The body 110 forms an open end through which cables 101, 102 may extend through the body 110 along the longitudinal axis 11 between a first end 103 and a second end 104. The first end 103 forms an end for allowing a plurality of optical fibers to extend through the body 110, such as depicted at the optical fiber tail 101. The optical fiber tail 101 may be configured as a fiber fork tail in which each tube or tail includes a single or more optical fibers, or as a fiber fork ribbon tail (e.g., ribbon-type), or as a pre-terminated optical fiber tail, etc. The optical fiber tail 101 may include any suitable optical fiber connector (e.g., Figure 29 to Figure 30 Connectors 105) depicted in the figure, such as but not limited to ST, LC, SC, MT, MPO, MPT and the like.

[0049] refer to Figures 1 to 4In various embodiments, the assembly 100 includes a body 110 including split portions, halves, or longitudinally extending sidewalls, such as body portions 110A, 110B. Portions 110A, 110B may include alignment and retention features, such as protrusions 116A, configured to be inserted, mated, or received at recesses 116B at the paired bodies 110A, 110B. In some embodiments, the retention features 116A, 116B may extend along the longitudinal axis 11, such as along a substantial length of the body 110 between the open ends 103, 104. In other embodiments, the retention features 116A may form a peg, shaft, or wall extending in the same direction as the retention features 116B (which form a recess, hole, slot, or groove in the body 110). In some embodiments, portions 110A, 110B are configured to be generally symmetrical with respect to one another. For example, retention features 116A may extend generally in the same direction as retention features 116B, thereby allowing each portion 110A to generally mirror each other. Thus, body 110 may include a pair of portions 110A configured to mate with each other to form cavity 118 therebetween.

[0050] A cavity 118 is formed in the body 110 that extends along the longitudinal axis 11. In various embodiments, the body 110 can form a cavity 118 having an outwardly expanding, diverging, or increasing cross-sectional area at the first end 103 relative to the second end 104 or a region therebetween. In some embodiments, the first end 103 at the body 110 forms an opening 112 of generally rectangular cross-section. The first end 103 is configured to receive a first end cap 120 that includes a first end cap body 122 and a mechanical retainer 124, such as a clip, that is configured to be selectively attached to the body 110. The first end cap 120 can also form a generally rectangular cross-sectional opening corresponding to the first end 103, thereby allowing the optical fiber pigtail 101 to extend therethrough.

[0051] In yet other embodiments, the second end 104 at the body 110 forms an opening 114 of a generally circular, oval, or elliptical cross-section. The second end 104 is configured to receive a second end cap 132 that includes an attachment interface 136 for a cable jacket or shield 130. The attachment interface 136 may form threads, raised walls, a pipe joint, or other surfaces configured to receive the shield 130. The second end cap 132 may also include a mechanical retainer 134, such as a clip, configured to be selectively attached to the body 110 at the second end 104. The mechanical retainers 124, 134 may form any suitable fit, such as a press fit, a snap fit, thereby allowing a user to selectively and releasably attach the caps 120, 132 to the body 110.

[0052] Exemplary embodiments of methods for constructing adaptive cable assemblies allow for a single multi-pass fusion splice and all-mechanical (e.g., free of resins, epoxies, sealants, etc.) or substantially all-mechanical retention of components to the cable. For example, the method may include extending a fiber optic pigtail assembly (e.g., optical fiber 101) including a plurality of optical fiber pigtails through a first end cap 120. The method may include connecting a terminal end of pigtail 101 to a fiber optic connector (e.g., Figure 29 to Figure 30 105 depicted in ). Each tail may include one or more optical fibers housed in a buffer tube. The method includes splicing an optical fiber from the cable 102 and an optical fiber from the tail assembly 101. The method may include connecting a packaging material 106 to the tail 101 at a splicing point of the cable 102. For example, the packaging material 106 including a splice protector and the spliced ​​leads 108 is arranged at a cavity 118 inside the body 110. For example, the body portions 110A and 110B are pressed, snapped, clamped, or otherwise matched together to position the spliced ​​leads 108 in the cavity 118. The spliced ​​leads 108 may include a splice protector that surrounds the splicing point between the leads 108A and 108B. Additionally or alternatively, the spliced ​​leads 108 may be positioned in the cavity 118, and the packaging material (e.g., resin) may be provided through an opening 126 at the body 110. The method may include coupling the shield 130 to the cable 102 at the second end 104 and coupling the front end cap 120 at the first end 103. In some embodiments, the protective jacket 140 is coupled to the shield 130 and extends over a portion of the cable 102.

[0053] Reference now Figures 5 to 10 In various embodiments, the assembly 100 includes a body 110 that includes split portions or halves, such as bodies 110A, 110B, and Figures 1 to 4 The body 110 can include a converging-diverging cross-sectional area, wherein a middle section 119 of the cavity 118 forms a larger cross-sectional area than one or both of the ends 103, 104. In various embodiments, the middle section 119 of the cavity 118 is about 35% to about 65% of the longitudinal distance extending from the ends 103, 104 (e.g., about 35% to 65% of the longitudinal distance between the ends 103, 104).

[0054] The body 110 may include an attachment interface 136 forming a clip, retainer, tab or other mechanical retention device at the second end 104. The attachment interface 136 may be formed as an integral part of the body 110, such as at each body portion 110A, 110B at the second end 104. The body 110 may include an opening 126 extending from the side wall of the body from the exterior to the cavity 118 to allow a sealant or resin to flow into the cavity 118. The body 110 may include a retention member 138 at the first end 103. The retention member 138 may form a tooth, fork, peg or other member extending from the inner wall of the body 110 into the cavity 118. The retention member 138 is configured to contact the tail 101, thereby promoting adhesion of the tail 101 to the body 110. The retention member 138 may be formed as an integral part of the body 110, such as at each body portion 110A, 110B at the first end 103.

[0055] An exemplary embodiment of a method for constructing an adaptive cable assembly allows for a fiber pigtail assembly with resin filling. Embodiments of the method may include a multi-fiber pigtail such as described above. The fiber pigtail 101 may include one or more optical fibers, a strength member (e.g., aramid yarn or other suitable material) and a surrounding jacket. Two or more pigtails 101 may be combined or adhered together to form pigtail subassemblies 101A, 101B. For example, the individual fiber pigtails included in the pigtail subassemblies 101A, 101B may be combined in groups (grounds) of three (3), or six (6), or nine (9), or twelve (12) pigtails, thereby improving the processing of multiple splices. The pigtail subassemblies 101A, 101B may include a double pigtail unit of approximately 1.6 millimeters (mm) or less.

[0056] Embodiments of the method may include splicing optical fibers from the cable 102 and the optical fibers at the tail 101. In some embodiments, the method may include splicing the optical fibers at the tail assembly 110 to the corresponding optical fibers at the cable 102. The method may include coupling the encapsulating material 106 to the spliced ​​leads 108. In some embodiments, the method includes coupling a resin, splice protector, jacket, or other material per quantity of optical fibers joined in a common fusion (e.g., per bundle of tails 101A, 101B). The spliced ​​leads 108, encapsulating material 106, and cable 102 are positioned at the body 110. For example, the spliced ​​leads 108, encapsulating material 106, and cable 102 may be positioned at the portion 101A. Portion 101B may be joined to portion 101A, such as by retention features 116A, 116B, such that body 110 surrounds the spliced ​​leads 108, encapsulation material 106, and the ends and tails 101 of cable 102 (e.g., tails 101A, 101B, etc.). An embodiment of the method includes coupling shield 130 to second end 104 of body 110 (e.g., second end 104 of joined portions 110A, 110B). The method may include injecting a sealant or resin (e.g., a two-part resin) into cavity 118 through opening 126 to mechanically strengthen assembly 100, secure tail 101 and cable 102 to body 110, and protect spliced ​​leads 108. The method may include positioning a portion of the cable 102 , such as portion 102A having an aramid or cable jacket, into the cavity 118 , thereby allowing the resin to contact and attach to the portion of the cable 102 at the cavity 118 and form a strength member for the cable 102 .

[0057] Embodiments of the method may allow flexibility or customization of the number of fibers passing through body 110. Resin filling through openings 126 may facilitate such strengthening, may improve cable retention at body 110, and may improve fiber and splice protection.

[0058] Reference now Figures 11 to 15 In various embodiments, the assembly 100 includes a body 110, such as Figures 1 to 10 The body 110 may include a diverging or increasing cross-sectional area, wherein the first end 103 forms a larger area of ​​the cavity 118 than the second end 104. The body 110 may form an integral, unitary component. For example, the body 110 may form a tubular component including a transition cross-section between the first end 103 (e.g., a rectangular cross-section) and the second end 104 (e.g., a circular cross-section). The first cross-sectional area (e.g., along a first side, such as a width) may extend along a length from the second end 104 to the first end 103, such as Fig.15The second cross-sectional area (eg, along the second side, such as the height) may be substantially constant along the length extending from the second end 104 to the first end 103, such as Fig.14 . The assembly 100 may include a first end cap 120 including a split first end cap body 122 including portions 122A, 122B. The first end cap 120 (such as portions 122A, 122B) allows the tail 101 to extend therethrough and snap, clip, contact, or otherwise attach around the tail 101.

[0059] An exemplary embodiment of a method for constructing an adaptive cable assembly allows a fiber tail assembly having a resin filler and a tail assembly 101 to be spliced ​​to the end of a cable 102. As described herein, the tail assembly 101 may include a plurality of tail subassemblies (e.g., tails 101A, 101B, etc.), thereby allowing the total number of optical fibers to be adapted or customized. For example, the tail assembly 101 may include one or more optical fibers, a strength member (e.g., an aramid yarn or other suitable material) and a surrounding jacket, wherein two or more tails 101A, 101B are combined together to form a tail subassembly. The terminal end of the tail 101 may include an optical fiber connector as described herein. The method may include splicing the optical fiber from the tail assembly 101 at the first end 103 to the cable 102 at the second end 104. For example, the method may include splicing the optical fiber multi-way fusion at the tail assembly 101 to the corresponding optical fiber at the cable 102. The packaging material 106 may be disposed at the spliced ​​lead 108. For example, a splice protector may be provided for each set of optical fibers (e.g., 101A, 101B) that are spliced ​​in a common fusion process. A splice assembly including a tail assembly 101 and a cable 102 is positioned in a body 110 (e.g., at a cavity 118). The method includes positioning a shroud 130 at the body 110. In one embodiment, the shroud 130 is disposed around a second end cap 132, and the second end cap 132 is coupled to the body 110 at the second end 104. In some embodiments, the method includes injecting or otherwise disposing a resin through an opening 126 at the body 110 to mechanically strengthen the assembly to secure the tail and the cable together, or to protect the spliced ​​leads 108.

[0060] Reference now Figures 16 to 19 In various embodiments, the assembly 100 includes a body 110, such as Figures 11 to 15 The body 110 may also include an attachment interface 136 that forms threads, raised walls, a fitting, or other surfaces configured to receive the shield 130. The attachment interface 136 may be integrally formed with the body 110, thereby forming the body 110 as a unitary, unitary component.

[0061] Reference now Figure 20 to Figure 23 In various embodiments, the assembly 100 includes a body 110, such as Figures 1 to 10 The body 110 may be formed as a split body having portions 110A, 110B, such as described herein. The body 110 may be formed as a substantially circular cross-section extending from the first end 103 to the second end 104. The cross-sectional area may form a converging-diverging cross-sectional area including a maximum area at the middle section 119. A larger cavity 118 (e.g., a substantially circular cross-sectional area, an increased middle cross-sectional area, or both) may allow for a larger number of optical fibers (e.g., 24 or more optical fibers, such as, but not limited to, 72, 96, 144, 288, or 576, etc.).

[0062] An exemplary embodiment of a method for constructing an adaptive cable assembly includes the steps as described above.In addition, the cable jacket and strength member at portion 102A may further extend through second end 104 and into resin-filled cavity 118 to provide mechanical fixation as described above.

[0063] Various embodiments of methods for constructing adaptive cable assemblies can allow for assembly of a connectorized tail 101 at a first location (e.g., at a first facility) and assembly to a main fiber optic cable 102 at a second location (e.g., at an installation point). Embodiments of the method can include terminating a multi-fiber cable assembly (e.g., tail 101). Terminating a multi-fiber cable assembly can include multi-way ribbon splicing of at least six (6) optical fibers per splice. The method can include multi-way fusion splicing of one or more multi-tail assemblies (e.g., tail assemblies 101A, 101B) to optical fibers at a fiber optic cable (e.g., cable 102). In some embodiments, the multi-way splicing includes splicing the tail to a rollable flexible ribbon optical fiber or discrete loose optical fibers at a high fiber count cable (e.g., cable 102).

[0064] In certain embodiments, the method includes splicing at least 12 optical fiber pigtails or subunits thereof using a two millimeter diameter round cable / furcation having an aramid strength member.

[0065] In certain other embodiments, the method includes splicing a pigtail of at least 24 optical fibers or subunits thereof using a three millimeter diameter round cable / furcation having an aramid strength member.

[0066] The body 110 may include a length between about 60 millimeters and about 200 millimeters (mm) along the longitudinal direction. Figures 1 to 4 The described embodiments may include a body 110 having a length between about 60 mm and about 80 mm, or about 65 mm. Figures 5 to 10 The described embodiment may include a body 110 having a length between about 155 mm and about 185 mm or about 170 mm. Figures 11 to 15 The described embodiments may include a body 110 having a length between about 170 mm and about 200 mm, or about 185 mm. Figures 16 to 19 The described embodiment may include a body 110 having a length between about 85 mm and about 115 mm, or about 100 mm. In yet another example, with respect to Figure 20 to Figure 23 The depicted embodiment may include a body 110 having a length between about 185 mm and about 200 mm.

[0067] The body 110 may include a space within the body 110 (eg, at the cavity 118) of approximately 108 square millimeters (mm 2 ) and about 616mm 2 For example, the maximum cross-sectional area can be at the middle section 119, such as described with respect to the converging-diverging cross-sectional area. In some embodiments, the maximum cross-sectional area is located at the middle section 119 and includes a substantially circular cross-sectional area. In various embodiments, such as described with respect to Figure 20 to Figure 23 As described, the maximum cross-sectional area is up to about 616 mm 2 In another example, the maximum cross-sectional area may be at the first end 103, such as about Figures 1 to 4 or Figures 11 to 19 The maximum cross-sectional area at the first end 103 may be approximately 108 mm 2 With about 216mm 2 The maximum cross-sectional area at the first end 103 can be a substantially rectangular cross-sectional area. In some embodiments, the maximum cross-sectional area at the first end 103 including the substantially rectangular cross-sectional area can include a first dimension (e.g., height) that is greater than a second dimension (e.g., width). The second dimension can be between about 60% and about 75% of the first dimension.

[0068] In various embodiments, the minimum cross-sectional area may be located at the second end 104. For example, the minimum cross-sectional area may be formed to include approximately 9 mm 2 The opening is to receive a connector / aramid crimp, such as to secure a strength member at the cable 102 to the rear of the cable branch or to hold the rear of the cable 102 together.

[0069] Reference now Fig.24 , a flowchart outlining exemplary steps of a method for constructing an adaptive cable assembly (hereinafter referred to as "method 1000") is provided. The steps of method 1000 may include forming a method such as about Figures 1 to 23The structure, coupling, splicing or connection described in the adaptive cable assembly 100 of . However, it should be appreciated that the steps of method 1000 can include other structures and steps for optical fiber cable assemblies, such as provided herein.

[0070] Method 1000 includes coupling connectors (e.g., one or more connectors) to form a connectorized optical fiber pigtail assembly at 1002. In various embodiments, step 1002 can occur at a low-cost manufacturing location (e.g., a first assembly location) relative to other steps of method 1000. Pigtail assemblies (e.g., pigtail assembly 101) can be produced at a high volume and relatively low cost at the first assembly location.

[0071] Embodiments of method 1000 may include preparing the optical fiber pigtail assembly for splicing at 1004. Method 1000 may include, at 1004, cutting the pigtail assembly into a predetermined length, positioning the optical fiber into a fiber holder, or shearing the optical fiber. For example, Fig.28 An embodiment of the assembly 100 is depicted without the connector installed. Fig.29 An embodiment of an assembly 100 is depicted in which a method 1000 couples a connector 105 to an end of a fiber optic pigtail assembly 101 at step 1002. The fiber optic pigtail assembly 101 may include a plurality of pigtail subassemblies 101A, 101B, 101C, 101D, etc. Fig.30 An embodiment of an assembly 100 is depicted that includes an optical fiber pigtail 101 operably coupled to a connector 105. Embodiments of the method 1000 may be performed at step 1004 at a second assembly position that is different than the first assembly position.

[0072] Method 1000 includes performing a multi-way fusion splicing of optical fibers from a fiber optic cable (e.g., cable 102) and optical fibers from a connectorized fiber optic pigtail assembly (e.g., pigtail assembly 101) at 1010, such as described in various embodiments herein. Method 1000 forms a multi-way fusion splice at a cable assembly at 1010. In various embodiments, method 1000 includes performing a multi-way fusion splicing of optical fibers from the fiber optic cable and optical fibers from the fiber optic pigtail assembly at a second assembly location at 1010. The second location may include an inside-plant (ISP) location or an outside-plant (OSP) location, such as an installation point, a repair point, or a reconfiguration point. In some embodiments, splicing the optical fibers may include a multi-way ribbon splicing of at least six (6) optical fibers per splice.

[0073] In various embodiments, the tail assembly is constructed at a first location (e.g., step 1002), and the multi-way fusion splicing is performed at a second location different from the first location (e.g., step 1010). Before performing the multi-way splicing, splicing preparation can be performed at the second location. For example, referring to Figure 25 to Figure 27 , method 1000 can utilize splicing device 200 at 1004 to perform the steps of method 1000. In various embodiments, method 1000 can include positioning optical fiber pigtails from a pigtail assembly (e.g., optical fiber pigtail 108A from pigtail assembly 101) and cables (e.g., optical fiber pigtail 108B from cable 102) into a splicing device (e.g., splicing device 200). Exemplary embodiments of splicing device 200 can include a splicing tool 210 that includes one or more clamps 220. Splicing tool 210 can also include positioning ribs, clamps, channels, or other components to desirably position, arrange, or hold optical fibers in a fixed position. Splicing tool 210 can be configured to perform fusion splicing, multi-pass fusion splicing, or other splicing methods as understood in the art.

[0074] In some embodiments, method 1000 includes, at 1020, arranging a splice protector at a splice point (e.g., at a multi-way fused splice) of the optical fiber cable and the optical fiber pigtail assembly (e.g., the spliced ​​leads 108A, 108B). In various embodiments, the encapsulating material may include a resin, a splice protector, a resin, or a combination thereof. In some embodiments, method 1000 includes, at 1020, positioning a splice protector at a splice point (e.g., a multi-way fused splice) at the spliced ​​leads, such as at a splice protector. Figure 26 to Figure 27 As depicted in FIG. 1 , the encapsulation material 106 at the spliced ​​leads 108A, 108B.

[0075] The method 1000 includes positioning a spliced ​​lead (such as a multi-way fused splice) having a splice protector into a cavity at a body (eg, cavity 118 at body 110) at 1030. For example, referring to Figure 25 to Figure 26 , an embodiment of the body 110 is configured as a split body including portions 110A, 110B separated from each other along a longitudinal axis (e.g., in the same direction as the extension of the optical fiber). The method 1000 may include joining the split body portions to each other at 1032 to enclose the spliced ​​leads (e.g., the spliced ​​leads 108A, 108B) in a cavity (e.g., cavity 118) formed by the joined portions (e.g., portions 110A, 110B). For example, the portions 110A, 110B may be as described with respect to Figures 1 to 10 and Figure 20 to Figure 23 snap, bond or otherwise adhere to each other as described.

[0076] In yet other embodiments, method 1000 may include extending the body into the cavity around the spliced ​​leads at 1034. For example, referring to Figures 11 to 19 and Fig. 27, embodiments of the body 110 are configured as an integral, single component. During splicing (e.g., step 1010), the body 110 is positioned adjacent to the splicing device 200. The body 110 slides in the same direction as the extension of the optical fiber to position the spliced ​​pigtails 108A, 108B within the cavity 118 in the body 110.

[0077] The method 1000 may also include, at 1030, extending the tail assembly through a first end cap (eg, first end cap 120) at 1036, and extending the cable assembly through a second end cap at 1038, such as with respect to Figures 1 to 10 and Figure 20 to Figure 23 Depicted and described.

[0078] Embodiments of assembly 100 including body 110 having portions 110A, 110B may allow, for example, when performing step 1010 (such as Fig.26 ) the shield 130 is positioned closer to the splicing device 200. For example, the body 110 forming a single structure can be positioned adjacent to the splicing device 200, and the shield 130 can be positioned adjacent to the body 110, such as Fig. 27 Thus, the split body can facilitate the use of shorter lengths of cable 102 as compared to a single body, such as can improve setup time and result in less space required for splicing.

[0079] The method 1000 may include providing an encapsulation material (e.g., resin) into the cavity surrounding the spliced ​​leads at 1040. For example, the resin may be injected through a first opening 126A that is located closer to the middle portion than a second opening 126B that is closer to the open ends 103, 104. The method 1000 may include providing the encapsulation material through one or more of the openings 126A at 1040 until the encapsulation material flows out of one or more of the openings 126B.

[0080] The method 1000 may also include positioning a cable jacket or shroud around the end portion of the cable and body at 1050. For example, the shroud 130 may be slid from around the cable 102 toward the body 110 to surround the attachment interface 136 at the end of the body 110. Fig.30 An embodiment of an assembly 100 is depicted that includes a body 110 , a cable 102 , and a tail assembly 101 operably coupled to one another, such as according to an embodiment of a method 1000 .

[0081] Embodiments of the assembly 100 and method 1000 provided herein may include a split transition module, multiple multi-way splices in a single transition module, splice protection integrated into the transition module, cable and tail tensile load connectors, an integral tail protection cover, (one or more) integral pull features, and the processing of connector leads and tail components. Embodiments of the assembly 100 and method 1000 may include a combination of maximum lengths or cross-sectional areas as provided herein, so as to advantageously provide structures and methods that allow splicing, splice protection, and resin filling as described herein. Embodiments provided herein may allow the controlled bipolarity of the tail component (e.g., end A has an alpha polarity and end B has a beta polarity, or end A and end B have the same polarity, or polarity method F is used to control the polarity of the tail and the two ends).

[0082] The embodiment of assembly 100 and method 1000 provided herein can allow the fast and low labor final assembly of medium to high fiber count cable assembly, and / or solve one or more of the above-mentioned problems recognized.For example, the core element of assembly 100 can include prefabricated tail assembly 101, sub-unitization or forked cable 102 and multi-way splicing and transition closure.Labor-intensive tail assembly 101 can be spliced ​​with low cost in large quantities relative to the scene (for example, installation point).By splicing the cable cut into a certain length to the tail assembly, high fiber count termination cable assembly can be produced on demand.In certain embodiments, the adaptive cable assembly such as described and described herein and the method for construction can be used for manufacturing complex assembly, repairing the cable in use or reconfiguring the installed cable at the installation point.

[0083] In an exemplary embodiment, the total fiber count can range from about 8 to about 576 fibers or more. In some embodiments, the tail assembly can include 8 to 24 fibers and include one to four multi-way fusion splice connectors to connect individual tail assemblies to cables or cable subunits. However, it should be appreciated that greater fiber counts can be included in embodiments of the assembly 100 and method 1000 described herein without departing from the scope of the present disclosure.

[0084] Further aspects of the invention are provided by one or more of the following embodiments:

[0085] 1. A method for constructing an adaptive cable assembly, the method comprising performing multi-way fusion splicing on optical fibers at a cable and optical fibers at a connectorized optical fiber pigtail assembly; and positioning the multi-way fusion splice in a cavity extending along a longitudinal axis, the cavity being formed by a body extending along the longitudinal axis, the body forming a first open end along the longitudinal axis, when the multi-way fusion splice is positioned in the cavity, the connectorized optical fiber pigtail assembly extends through the first open end, the body forming a second open end along the longitudinal axis, when the multi-way fusion splice is positioned in the cavity, the optical fiber cable extends through the second open end.

[0086] 2. A method according to any one or more of the clauses herein, wherein the tail component is constructed at a first location and the multi-way fusion splicing is performed at a second location different from the first location.

[0087] 3. A method according to any one or more of the clauses herein, comprising providing encapsulation material into the cavity surrounding the multi-way fused splice.

[0088] 4. The method of any one or more of the clauses herein, wherein providing the encapsulation material comprises injecting a resin through a first opening extending from a longitudinal sidewall of the body between the first open end and the second open end.

[0089] 5. The method of any one or more clauses herein, wherein providing the encapsulation material comprises injecting the resin through the first opening until the resin flows out through a second opening proximate one or both of the first open end and the second open end.

[0090] 6. A method according to any one or more of the clauses herein, wherein the body comprises longitudinal side walls separated along the longitudinal axis, wherein positioning the multi-way fused splicing portion in the cavity comprises attaching the longitudinal side walls to each other to form the cavity and positioning the multi-way fused splicing portion in the cavity.

[0091] 7. A method according to any one or more of the clauses herein, comprising coupling together longitudinal side walls of the body to position the multi-way fusion splice at the cavity.

[0092] 8. A method according to any one or more of the clauses herein, wherein coupling the longitudinal side walls of the body together comprises coupling retention features at the respective longitudinal side walls to each other.

[0093] 9. The method of any one or more of the clauses herein, wherein forming a multi-way fused splice comprises multi-way splicing of optical fibers with at least six optical fibers per splice.

[0094] 10. A method according to any one or more clauses herein, comprising placing a splice protector onto a splice point of the multi-way fused splice prior to positioning the multi-way fused splice in the cavity.

[0095] 11. A method according to any one or more of the clauses herein, the method comprising extending the optical fiber tail assembly through a first end cap; extending the optical fiber cable through a second end cap; and after performing a multi-way fusion splice and positioning the multi-way fusion splice at the cavity, connecting the first end cap to the first open end at the body and connecting the second end cap to the second open end at the body.

[0096] 12. A method according to any one or more of the clauses herein, wherein the body forms a single, unitary longitudinal structure, wherein positioning the multi-way fused splice in the cavity comprises sliding the body around the multi-way fused splice to position the multi-way fused splice in the cavity.

[0097] 13. The method of any one or more of the clauses herein, wherein the connectorized fiber optic pigtail assembly comprises from about 8 optical fibers to about 576 optical fibers.

[0098] 14. A method as described in any one or more of the clauses herein, wherein the optical fiber pigtail assembly comprises a plurality of pigtail sub-assemblies.

[0099] 15. A method according to any one or more clauses herein, wherein multi-way fusion splicing of optical fibers at the cable and at the connectorized optical fiber pigtail assembly includes forming one or more multi-way fusion splices to connect multiple pigtail subassemblies to the optical fiber cable.

[0100] 16. A method according to any one or more clauses herein, wherein the method comprises coupling halves of a split first end cap to each other and to the plurality of tail subassemblies at a first open end.

[0101] 17. A method according to any one or more clauses herein, comprising positioning a shroud around a second end cap at a second open end of the body; and coupling the shroud to a fiber optic cable extending through the second open end.

[0102] 18. A cable assembly comprising a body extending along a longitudinal axis, the body forming a first open end and a second open end along the longitudinal axis, the first open end forming a substantially rectangular cross-sectional area and the second open end forming a substantially circular cross-sectional area, the body forming a cavity extending along the longitudinal axis, wherein an attachment interface is positioned at the second open end, the attachment interface forming a raised wall or a clip, the raised wall or the clip being configured to receive a shield.

[0103] 19. The cable assembly of any one or more clauses herein, wherein the body comprises a separable longitudinal side wall extending along the longitudinal axis.

[0104] 20. The cable assembly of any one or more clauses herein, wherein the body forms a diverging cross-sectional area at the cavity extending from the second open end to the first open end, wherein the first open end comprises a maximum cross-sectional area.

[0105] 21. The cable assembly of any one or more of the clauses herein, wherein the maximum cross-sectional area is between approximately 108 square millimeters and approximately 216 square millimeters.

[0106] 22. A method according to any one or more of the clauses herein, the method comprising forming a body extending along a longitudinal axis; forming a first open end at the body along the longitudinal axis; extending a connectorized optical fiber tail assembly through the first open end when a multi-way fusion splice is positioned in a cavity; forming a second open end at the body along the longitudinal axis; and extending an optical fiber cable through the second open end when the multi-way fusion splice is positioned in the cavity.

[0107] 23. A method for constructing a cable assembly as described in any one or more of the clauses herein, the method comprising: performing multi-way fusion splicing of optical fibers at a cable and optical fibers at a connectorized optical fiber tail assembly; and positioning the multi-way fusion spliced ​​portion in a cavity extending along the longitudinal axis formed by a body extending along the longitudinal axis.

[0108] 24. A method for constructing a cable assembly as described in any one or more of the clauses herein, the method comprising forming a body extending along a longitudinal axis; forming a first open end at the body along the longitudinal axis; extending a connectorized fiber optic tail assembly through the first open end when a multi-way fusion splice is positioned in a cavity; forming a second open end at the body along the longitudinal axis; and extending a fiber optic cable through the second open end when the multi-way fusion splice is positioned in the cavity.

[0109] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A method for constructing an adaptive cable assembly, the method comprising: Perform multi-channel fusion splicing of optical fibers at the cable and optical fibers at the connectorized optical fiber tail assembly; as well as The multi-way fusion splice is positioned in a cavity extending along a longitudinal axis, the cavity being formed by a body extending along the longitudinal axis, the body forming a first open end along the longitudinal axis, the connectorized optical fiber pigtail assembly extending through the first open end when the multi-way fusion splice is positioned in the cavity, the body forming a second open end along the longitudinal axis, the optical fiber cable extending through the second open end when the multi-way fusion splice is positioned in the cavity.

2. The method according to claim 1, wherein: The tail assembly is constructed at a first location, and the multi-way fusion splicing is performed at a second location different from the first location.

3. The method according to claim 1, comprising: A potting material is provided into the cavity surrounding the multi-way fused splice.

4. The method according to claim 3, wherein: Providing the encapsulation material includes injecting a resin through a first opening extending from a longitudinal sidewall of the body between the first open end and the second open end.

5. The method according to claim 4, wherein: Providing the encapsulating material includes injecting the resin through the first opening until the resin flows out through a second opening proximate one or both of the first open end and the second open end.

6. The method of claim 1, wherein the body comprises longitudinal side walls separated along the longitudinal axis, wherein: Positioning the multi-way fused splice in the cavity includes attaching the longitudinal side walls to each other to form a cavity and positioning the multi-way fused splice within the cavity.

7. The method according to claim 1, comprising: The longitudinal side walls of the body are coupled together to position a multi-way fusion splice at the cavity.

8. The method according to claim 7, wherein: Coupling the longitudinal side walls of the body together includes coupling retention features at the respective longitudinal side walls to each other.

9. The method according to claim 1, wherein: Forming a multi-way fusion splice includes multi-way splicing of optical fibers in a manner that each splice has at least six optical fibers.

10. The method according to claim 1, comprising: Prior to positioning the multi-way fused splice in the cavity, a splice protector is placed onto the splice points of the multi-way fused splice.

11. The method according to claim 1, comprising: extending the optical fiber pigtail assembly through the first end cap; extending the fiber optic cable through the second end cap; After performing the multi-way fused splice and positioning the multi-way fused splice at the cavity, a first end cap is coupled to the first open end at the body and a second end cap is coupled to the second open end at the body.

12. The method of claim 1, wherein the body forms a single, unitary longitudinal structure, wherein: Positioning the multi-way fused splice in the cavity includes sliding the body around the multi-way fused splice to position the multi-way fused splice within the cavity.

13. The method according to claim 1, wherein: Connectorized fiber pigtail assemblies include from about 8 optical fibers to about 576 optical fibers.

14. The method according to claim 1, wherein: The optical fiber pigtail assembly includes a plurality of pigtail subassemblies.

15. The method according to claim 14, wherein: Performing a multi-way fusion splice of optical fibers at the cable and at the connectorized fiber optic pigtail assembly includes forming one or more multi-way fusion splices to connect the plurality of pigtail subassemblies to the fiber optic cable.

16. The method according to claim 14, wherein: The method includes coupling halves of a split first end cap to each other and a plurality of tail subassemblies at a first open end.

17. The method according to claim 1, comprising: positioning a shield around a second end cap at a second open end of the body; as well as The shroud is coupled to a fiber optic cable extending through the second open end.

18. A cable assembly, comprising: A body extending along a longitudinal axis, the body forming a first open end and a second open end along the longitudinal axis, the first open end forming a generally rectangular cross-sectional area and the second open end forming a generally circular cross-sectional area, the body forming a cavity extending along the longitudinal axis, wherein an attachment interface is positioned at the second open end, the attachment interface forming a raised wall or clip, the raised wall or clip being configured to receive a shield.

19. The cable assembly of claim 18, wherein: The body includes a separable longitudinal sidewall extending along the longitudinal axis.

20. The cable assembly of claim 19, the body forming a diverging cross-sectional area at the cavity extending from the second open end to the first open end, wherein: The first open end comprises a maximum cross-sectional area, and wherein the maximum cross-sectional area is between approximately 108 square millimeters and approximately 216 square millimeters.

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