Cable assembly for distributed tap optical fiber network and method for forming same

Abstract

Provided are embodiments of a cable assembly. The cable assembly includes a distribution cable with a cable jacket. Optical fibers, including first and second fibers, are disposed within the cable jacket. One or more fiber access windows are formed through the cable jacket. The cable assembly further includes a tether with first and second tether fibers extending from the distribution cable at a branch point. The first optical fiber is cleaved and withdrawn from downstream of the fiber access window and spliced to the first tether fiber. The second optical fiber is cleaved and withdrawn from upstream of the fiber access window and is spliced to the second tether fiber. The first optical fiber provides optical continuity upstream of the first branch point, and the second optical fiber provides optical continuity downstream of the first branch point. The fiber access window, an end of the tether, and the cable jacket are covered by an overmold.

Description

Attorney Docket No.: HI24-133PCTCABLE ASSEMBLY FOR DISTRIBUTED TAP OPTICAL FIBER NETWORK AND METHOD FOR FORMING SAMECROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 725,601, filed on November 27, 2024, and U.S. Provisional Application 63 / 759,637, filed on February 18, 2025, the content of each of which is relied upon and incorporated herein by reference in its entirety.BACKGROUND OF THE DISCLOSURE

[0002] The present disclosure generally relates to cable assemblies and, in particular, cable assemblies for distributed tap optical fiber networks.

[0003] Optical fiber broadband networks are designed to distribute bidirectional traffic between a service provider and subscribers. The service provider transmits optical signals from optical line terminals (OLT) at a central hub to provide downstream optical broadband services to subscribers at the edge of the network and receives upstream signals transmitted by subscribers. Starting from the central hub, a distribution cable is deployed to carry optical signals for a portion of the network. The distribution cable has a first end and a second end, the first end being an upstream end extending from the central hub or spliced to other cables extending from the central hub. The second end is a downstream end extending into the distribution network. In between the first end and the second end, smaller branch cables are branched off the distribution cable to extend optical continuity deeper into the cable network providing optical continuity to network access points at the edge of the network such as multiports or terminals located near a group of subscribers. Drop cables can then be placed from the network access points to individual subscribers when subscribers are ready to take service.

[0004] The conventional means of creating a branch point between a distribution cable and branch cable is to create it in the field after the distribution cable has been deployed. A field technician breaches the distribution cable jacket in the field at a specified location between the first end and the second end, accesses selected fibers within a longitudinal bore inside the distribution cable and splices the selected fibers to the fibers of a branch cable to create a branch point. The resulting branch point is conventionally housed within a splice closure for mechanical and environmental protection.Attorney Docket No.: HI24-133PCT

[0005] When a subscriber takes service, optical signal is provisioned by deploying a drop cable from a network access point to an optical network unit (ONU) located at the subscriber. An alternative to creating branch points in the field is to factory-build a preengineered cable assembly including branch points located at customer specified locations along the assembly. This may involve breaching the distribution cable jacket at one or more specified locations between the first end and the second end in the factory, accessing selected fibers within a longitudinal bore inside the distribution cable and splicing the selected fibers to the fibers of one or more short tether cables to create the needed branch points. The short tether cables may be of any practical length and are usually terminated in the factory at the non-spliced end to form a cable assembly with one or more hardened optical connectors rated for outside plant conditions, though it is also possible to leave the unspliced ends of the tether cables unterminated, allowing for subsequent termination or splicing in the field.

[0006] Factory -built cable assemblies with branch points require mechanical and environmental protection of the branch point before leaving the factory. This protection is typically accomplished in the form of a plastic or elastomer overmold. The overmold, therefore, eliminates the need for a splice closure to protect the splices at the branch points.

[0007] There are many ways to optimize the cost, scaleability, serviceability and performance of an optical network by incorporating various passive optical devices into the network, such as tap couplers and splitters. Desirably, the tap couplers and splitters are placed and interconnected with cables in such a way as to optimize the delivery of optical signals with respect to right of way usage, cable and fiber utilization, optical power utilization, and the overall costs of initially building and then maintaining a scalable network over the expected life of the network. One means of optimizing an optical distribution network is to design the network as a distributed tap network. Such networks conventionally rely on the field method described above for creating branch points within splice closures. For distributed tap networks, the conventional field method has prevailed over the factory- built approach due to certain challenges uniquely characteristic of the more complex daisy chain splicing schematics needed for distributed tap networks. More specifically, the challenge involves accessing enough fiber slack from within the distribution cable to form the requisite splices at the branch point. These challenges are easily managed within the generous spatial confines of a splice closure, but until now, methods of managing these challenges within the tighter spatial confines of a factory overmold have not been developed. The subject matter of the disclosed invention pertains to novel and inventive fiber managementAttorney Docket No.: HI24-133PCT and splicing configurations needed to create branch points in the factory, thereby enabling a method to manufacture factory-built, pre-engineered cable assemblies suitable for use in distributed tap networks.SUMMARY OF THE DISCLOSURE

[0008] In describing the various aspects and embodiments of the present invention, it is practical to define the intended meaning of the terms “upstream” and “downstream”. Unless otherwise indicated, these terms are intended to describe relative schematic positioning of cable assembly features and / or optically coupled components within a broadband network. For example, where one cable assembly feature or optically coupled component has a shorter optical distance to the optical line terminal of a service provider or hub than another cable assembly feature or optically coupled component, the one closer to the optical line terminal or hub is said to be “upstream” of the other, or the other is said to be “downstream” of the closer one. These terms are not intended to describe directionality of signal transmission between service providers and subscribers, because bi-directional transmission of signals over a single fiber is permitted or specified according to multiple transmission protocols suitable for use in distributed tap networks.

[0009] In a first aspect, embodiments of the present disclosure relate to a cable assembly. The cable assembly includes a distribution cable having a first end, a second end, and a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable between the first and second end. A plurality of optical fibers is disposed within the at least one longitudinal bore, and the plurality of optical fibers comprises at least one first optical fiber and at least one second optical fiber. At least one first fiber access window is formed through the cable jacket to provide access to the at least one longitudinal bore. The cable assembly also includes at least one first tether having at least one first tether fiber and at least one second tether fiber in which the at least one first tether is spliced to, and extends from, the distribution cable at a first branch point. In the formation of the first branch point, the at least one first optical fiber is accessed through an at least one first fiber access window and cleaved. At least one second optical fiber is accessed through at least one fiber access window and cleaved, wherein the cleave point of the at least one first optical fiber is downstream of the cleave point of the at least one second optical fiber. The cleaving of each fiber produces two cleaved fiber ends. One is an upstream cleaved end which extends in the direction of the first end of the distribution cable and the other is a downstream cleaved end extending in the direction of the second end of the distributionAttorney Docket No.: HI24-133PCT cable. The upstream cleaved end of the at least one first optical fiber is withdrawn from the at least one longitudinal bore through a suitable first fiber access window and is spliced to the at least one first tether fiber outside of the at least one longitudinal bore. The downstream cleaved end of the at least one second optical fiber is withdrawn from the at least one longitudinal bore through a suitable first fiber first fiber access window and is spliced to the at least one second tether fiber outside of the at least one longitudinal bore. The resulting splices between the distribution cable and the at least one tether cable define a first branch point. The portion of the cleaved at least one first optical fiber extending from the first branch point in the direction of the first end of the distribution cable is thereby optically coupled at the branch point to the at least one first tether fiber of the at least one first tether. The portion of the cleaved at least one second optical fiber extending from the first branch point in the direction of the second end of the distribution cable is thereby optically coupled at the branch point to the at least one second tether fiber of the tether. The at least one first fiber access window, the first branch point, an end of the at least one first tether, and a portion of the cable jacket surrounding the first branch point may be covered by an overmold or other suitable protective covering.

[0010] In a second aspect, embodiments of the present disclosure relate to a method of forming a cable assembly. In the first step of the method a distribution cable is provided having a first end and a second end and further comprising a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable between the first and second ends. A plurality of optical fibers is disposed within the at least one longitudinal bore, and the plurality of optical fibers comprises at least one first optical fiber and at least one second optical fiber. In the second step of the method, at least one tether cable is also provided. The at least one first tether comprises at least one first tether fiber and at least one second tether fiber. The third step of the method comprises the formation of a first branch point by splicing fibers of the at least one first tether to fibers within the distribution cable at a point between the first and second ends of the distribution cable. In the formation of the first branch point, at least one first optical fiber is accessed through at least one first fiber access window and is cleaved. The at least one second optical fiber is accessed through at least one fiber access window and cleaved, wherein the cleave point of the at least one first optical fiber is downstream of the cleave point of the at least one second optical fiber. The cleaving of each fiber produces two cleaved fiber ends. One is an upstream cleaved end which extends in the direction of the first end of the distribution cable and the other is aAttorney Docket No.: HI24-133PCT downstream cleaved end extending in the direction of the second end of the distribution cable. The upstream cleaved end of the at least one first optical fiber is withdrawn from the at least one longitudinal bore through a suitable first fiber access window and is spliced to the at least one first tether fiber outside of the at least one longitudinal bore. In the fourth step of the method the at least one first fiber access window, the first branch point, an end of the at least one first tether, and a portion of the cable jacket surrounding the first branch point may be covered by an overmold or other suitable protective covering.

[0011] In a third aspect, embodiments of the present disclosure relate to a cable assembly. The cable assembly comprises a distribution cable having a first end and a second end and further comprising a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable between the first and second end. A plurality of optical fibers is disposed within the at least one longitudinal bore, and the plurality of optical fibers comprises at least one first optical fiber. The distribution cable further comprises a first fiber access window and a second fiber access window, the first fiber access window and the second fiber access window cut through the cable jacket to access the at least one first optical fiber within the at least one longitudinal bore. The first fiber access window is located closer to the first end of the distribution cable than the second fiber access window. The cable assembly further comprises at least one first tether comprising at least one first tether fiber and at least one second tether fiber in which the at least one first tether is spliced to, and extends from, the distribution cable at a first branch point. The first optical fiber is cleaved between the first fiber access window and the second fiber access window resulting in two cleaved fiber ends. One fiber end is associated with a portion of the first optical fiber that extends upstream in the direction of the first end of the distribution cable and a second cleaved fiber end associated with a portion of the first optical fiber that extends downstream in the direction of the second end of the cable. The cleaved fiber end associated with the upstream portion of the at least one first optical fiber is withdrawn from the at least one longitudinal bore of the distribution cable through the first access window and is spliced to the at least one first tether fiber outside of the at least one longitudinal bore. The cleaved fiber end associated with the portion of the at least one first optical fiber extending downstream toward the second end of the distribution cable is withdrawn from the second fiber access window and is spliced to the at least one second tether fiber outside of the at least one longitudinal bore. The resulting splices between the distribution cable and the at least one tether cable define a first branch point. The portion of the at least one first optical fiberAttorney Docket No.: HI24-133PCT extending from the first branch point in the direction of the first end of the distribution cable is optically coupled at the branch point to the at least one first tether fiber of the at least one first tether. The portion of the at least one first optical fiber extending from the first branch point in the direction of the second end of the distribution cable is thereby optically coupled at the branch point to the at least one second tether fiber of the at least one tether The first fiber access window, the at least one first branch point, an end of the at least one first tether, and a portion of the cable jacket surrounding the at the first branch point are covered by an overmold or other suitable protective covering.

[0012] In a fourth aspect, embodiments of the present disclosure relate to a method of forming a cable assembly. In the first step of the method a distribution cable is provided having a first end and a second end and further comprising a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable between the first and second ends. A plurality of optical fibers is disposed within the at least one longitudinal bore, and the plurality of optical fibers comprises at least one first optical fiber and at least one second optical fiber. In the second step of the method, at least one tether cable is also provided. The at least one first tether comprises at least one first tether fiber and at least one second tether fiber. The third step of the method comprises the formation of a first branch point by splicing fibers of the at least one first tether to fibers within the distribution cable at a point between the first and second ends of the distribution cable. In the third step of the method, a first fiber access window and a second fiber access window are opened through the cable jacket of a distribution cable to provide access to a plurality of optical fibers within at least one longitudinal bore defined by the cable jacket. The first optical fiber access window is located closer to the first end of the distribution cable than the second fiber access window. A first optical fiber of the plurality of optical fibers is cleaved at a location between the first fiber access window and the second fiber access window such that the first optical fiber comprises a first cleaved end associated with a portion of the first optical fiber extending upstream in the direction of the first end of the distribution cable and a cleaved fiber end associated with a portion of the first optical fiber extending downstream in the direction of the second end of the distribution cable. The cleaved end associated with the portion of the first optical fiber extending upstream in the direction of the first end of the cable is withdrawn from the first fiber access window, and the cleaved end associated with the portion of the first optical fiber extending downstream toward the second end of the distribution cable is withdrawn from the second fiber. The cleaved end associated with theAttorney Docket No.: HI24-133PCT portion of the first optical fiber extending upstream in the direction of the fist end of the distribution cable is spliced to a first tether fiber outside of the at least one longitudinal bore, and the cleaved end associated with the portion of the first optical fiber extending downstream in the direction of the second end of the distribution cable is spliced to the second tether fiber outside of the at least one longitudinal bore. The first fiber access window, the second fiber access window, the first branch point, an end of the at least one first tether, and a portion of the cable jacket surrounding the branch point are covered with an at least one overmold.

[0013] In accordance with yet other aspects of the present disclosure, embodiments of the present disclosure relate to a method of forming a cable assembly. In the first step of the method a distribution cable is provided having a first end and a second end and further comprising a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable between the first and second ends. A plurality of optical fibers is disposed within the at least one longitudinal bore, and the plurality of optical fibers comprises at least one first optical fiber. In the second step of the method, at least one tether cable is also provided. The at least one first tether comprises at least one first tether fiber and at least one second tether fiber. The third step of the method comprises the formation of a first branch point by splicing the at least one first tether fiber and the at least one second tether fiber of the at least one first tether to the at least first optical fiber within the distribution cable at a point between the first and second ends of the distribution cable. In the formation of the first branch point, a first fiber access window and a second fibers access window are formed by removing a portion of the cable jacket to expose a portion of the at least one optical fiber within the at least one longitudinal bore. The at least one first optical fiber is cleaved at a point between the first fiber access window and the second fiber access window, resulting in two cleaved fiber ends. One cleaved fiber end is associated with a portion of the first optical fiber extending upstream toward the first end of the cable. The other cleaved fiber end is associated with a portion of the first optical fiber extending downstream toward the second end of the cable. The resulting cleaved fiber end closest to the first end of the distribution cable is withdrawn from the at least one longitudinal bore at the second fiber access window and is spliced to the at least one first tether fiber outside of the at least one longitudinal bore. The resulting cleaved fiber end closest to the second end of the distribution cable is withdrawn from the at least one longitudinal bore at the first fiber access window and is spliced to the at least one first tether fiber outside of the at least oneAttorney Docket No.: HI24-133PCT longitudinal bore. The resulting at least two splices between the distribution cable and the at least one tether cable define the first branch point. The portion of the cleaved at least one first optical fiber extending from the first branch point in the direction of the first end of the distribution cable is thereby optically coupled at the branch point to the at least one first tether fiber of the at least one first tether. The portion of the cleaved at least one first optical fiber extending from the first branch point in the direction of the second end of the distribution cable is thereby optically coupled at the branch point to the at least one second tether fiber of the at least one tether. In the fourth step of the method the first fiber access window, the second fiber access widow, the at least one first branch point, an end of the at least one first tether, and a portion of the cable jacket surrounding the first branch point are covered by an overmold or other suitable protective covering.

[0014] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0015] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework to understanding the nature and character of the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments. In the drawings:

[0017] FIG. 1 depicts a schematic representation of a distributed tap optical fiber network, according to an exemplary embodiment;

[0018] FIGS. 2A-2E depict steps of a first method for splicing cleaved ends of two separate optical fibers of a distribution cable to two fibers of a tether cable to form a cable assembly comprising an overmolded branch point for use in a distributed tap optical fiber network, according to an exemplary embodiment; and

[0019] FIGS. 3 A-3D depict steps of a second method for splicing two cleaved ends of a single optical fiber of a distribution cable to two fibers of a tether cable to form a cableAttorney Docket No.: HI24-133PCT assembly comprising an overmolded branch point for use in a distributed tap optical fiber network, according to an exemplary embodiment.DETAILED DESCRIPTION

[0020] Embodiments of the present disclosure relate to novel and inventive branched distribution cable assemblies for use in a distributed tap optical network and methods of forming such branched distribution cable assemblies. According to conventional methods, when branching from a distribution cable is required, the optical fiber for which the signal is being branched is typically accessed after field deployment of the distribution cable by a method know as midspan accessing. Midspan accessing typically requires the removal of several feet of cable jacket from around the full circumference of the cable to access enough fiber slack to performing necessary splicing. With adequate fiber slack, the accessed fiber can be cleaved and one or both cleaved fiber ends can be extended to the platform of a fusion splicer where a splice technician can splice the fiber of the branch cable to the appropriate fiber or fibers of the distribution cable to form a branch point. The exposed fibers and splices resulting from these operations must subsequently be protected within a splice closure or cabinet. Typically, the branch cable will have two or more fibers extending to an asymmetric coupler elsewhere within the network with one fiber of the branch cable carrying an input signal to an asymmetric coupler which taps off a portion of power to serve a group of subscribers and another fiber of the branch cable returning untapped optical signal from the asymmetric coupler to the distribution cable. The conventional field build method, however, has several drawbacks including the fact that it requires the use of expensive highly skilled field labor, is subject to accidental fiber damage and a wide variety of installation errors during buildout, and it requires the installation and placement of splice closures or cabinet within limited right-of-way space.

[0021] As will be discussed more fully below, the branch points of the presently disclosed cable assemblies can be pre-engineered and formed in a factory environment, resulting in cable assemblies that can be more rapidly deployed to form a scalable distributed tap network with lower risk of installation and maintenance errors and requiring reduced use of highly skilled labor. These and other aspects and advantages of the disclosed cable assembly and method of forming same will be described in greater detail below and in relation to the accompanying figures. These exemplary embodiments are provided by way of illustration, and not by way of limitation.Attorney Docket No.: HI24-133PCT

[0022] FIG. 1 depicts an exemplary embodiment of a distributed tap optical fiber network 10, in particular schematically representing optical connectivity between optical fibers within a distribution cable assembly according to the present disclosure and passive optical devices (such as tap couplers and splitters) of an exemplary distributed tap network. In the distributed tap optical network 10, a distribution cable 12 comprising optical fibers 14 transmits optical signals over optical fibers 14 from an optical line terminal (OLT) 15 at a central hub, such as a central office, to a series of branch points 16 along the length of the distribution cable 12. At each branch point 16, an optical fiber 14 is spliced into a branch cable, which according to embodiments of the present invention is referred to as a tether 18, which contains at least a first tether fiber 46a and a second tether fiber 46b. As will be discussed more fully below, the first tether fiber 46a and the second tether fiber 46b provide a portion of the optical signal paths between the distribution cable and a series of asymmetric tap couplers within a split network 20. In the split network 20, the first tether fiber 46a is optically coupled to the input of an asymmetric tap coupler 22, either directly or by way of an intermediate cable extending between the tether and the asymmetric tap coupler. The second tether fiber 46b is optically coupled to an output of the asymmetric tap coupler 22, either directly or by way of an intermediate cable extending between the tether and the asymmetric tap coupler.

[0023] The asymmetric tap coupler 22 splits optical power of the optical signal into two portions. A first portion of the optical signal is output to the second tether fiber 46b, and a second portion of the optical signal is output to a network providing service to subscribers. In some embodiments the second portion of the optical signal is output to an input of a splitter 24, such as a IxN splitter, which may be integrated with, or physically collocated with the asymmetric tap coupler 22, for example, within a terminal or which may be located elsewhere in the network. When the asymmetric tap coupler 22 and the splitter 24 are not integrated or collocated, another optical fiber 17 may be provided to provide optical communication between the asymmetric tap coupler 22 and the splitter 24, which could be hundreds of meters away from the asymmetric tap coupler 22, for example. The asymmetric tap coupler 22 is referred to herein as “asymmetric” because the first portion of the optical power and the second portion of optical power are not necessarily equal. For example, starting with an optical power of 100% on the first tether fiber 46a, the asymmetric tap coupler 22 could tap 5% of the optical power to provide optical signal to the splitter 24, and the remaining 95% of optical power can be output to the second tether fiber 46b.Attorney Docket No.: HI24-133PCT

[0024] As shown in FIG. 1, splitter 24 divides the optical power into N number of equal divisions, which are output on N number of optical fibers which are typically terminated to N connection ports of one or more environmentally sealed multiport or terminals, thereby creating a network access point for the interconnection of up to N preterminated drop cables as subscribers take service over time. Alternatively, the N optical fibers may distribute the optical signal to other portions or components of the network.

[0025] As mentioned, one portion of the optical power of the optical signal is returned to the distribution cable 12 carried by the second tether fiber 46b. In this way, the returned portion of the optical signal continues further down the length of the distribution cable 12 until reaching the next branch point 16. At the next branch point 16, optical connectivity of the optical signal is provided to another tether 18 on a first tether fiber 46a of that tether 18. The optical power of the optical signal is split again in the split network 20 using an asymmetric tap coupler 22 and a splitter 24. The remaining portion of the optical power is returned on the second tether fiber 46b to the distribution cable 12, where the optical power is carried on an optical fiber 14 until reaching the next branch point 16. This sequential tapping of the optical power down the length of the cable assembly in this manner continues until the optical power is exhausted, and then, the process is repeated for the optical signal on another optical fiber 14 of the distribution cable 12.

[0026] The branch points 16 can be positioned at regular or irregular intervals along the length of the distribution cable 12 to form a series of branch points, the tether of each branch point providing optical connectivity to an asymmetric tap coupler within the series of asymmetric tap couplers. Further, the length of each tether 18 extending from each branch point 16 can be varied by design to optimize the practical accessibility of the tether within the distribution cable pathway. Additionally, the asymmetric tap couplers 22 within a series of asymmetric tap couplers can tap different percentages of input optical power in each of the split networks 20. In general, within a series of asymmetric tap couplers 22, each sequential tap coupler will tap an increasing percentage of the input optical power to maintain adequate optical power between the OLT 15 and the split network 20 in the distributed tap optical network 10 because the remaining optical power carried on the optical fiber 14 decreases with each branch point 16 within a series until power is depleted. For example, as shown in FIG. 1, a first asymmetric tap coupler 22 may tap 5% of the optical power, returning 95% of the optical power to the distribution cable 12. As shown in FIG. 1, the second asymmetric tap coupler 22 taps 10% of the 95% remaining optical power, providing 9.5% of the initialAttorney Docket No.: HI24-133PCT optical power to the splitter 24 and returning about 85.5% of the initial optical power to the distribution cable 12, and so on.

[0027] In the distributed tap optical network 10, an asymmetric tap coupler 22 refers to a passive optical device that receives input optical power from one optical fiber and divides an output power unevenly between two output optical fibers according to a desired power ratio. In one or more embodiments, the asymmetric tap coupler 22 can be any of a variety of asymmetric tap coupler types, such as a fused biconic tap (FBT) coupler or a planar light circuit (PLC) coupler. In one or more embodiments, the PLC coupler may include an integrated IxN splitter 24.

[0028] In one or more embodiments, the splitter 24 refers to a passive optical device which receives input power from at least one optical fiber and evenly divides power to N output optical fibers. Typically, the splitter is a IxN splitter and divides the signal power from 1 input optical fiber into N output fibers in which N is often one of 4, 8, 16, or 32.

[0029] Having described the general structure of the distributed tap optical network 10, the construction of the cable assembly, including the distribution cable 12 and branch points 16, is now described. Advantageously, the cable assembly is prepared in a factory (instead of in the field) where the cost of labor is lower, where the splice environment can be controlled, and where the branch points can be provided in smaller, more secure packages. In various embodiments, it will be noted that, within the distribution cable 12, not all optical fibers will necessarily maintain optical continuity to the OLT 15 or the split network 20 at all points throughout the length of the distribution cable 12. For example, at a first branch point, the optical signal of on the portion of a first optical fiber 14 extending upstream of the first branch point may be cleaved and routed out of the cable at the first branch point 16 to provide signal to a first split network 20, thereby disrupting optical continuity of the portion of first optical fiber 14 extending downstream of the first branch point 16 between the first branch point 16 and the second branch point 16. The optical signal returned from the first split network 20 is spliced into a second cleaved optical fiber 14 to provide optical continuity between the first branch point 16 and the second branch point 16 downstream of the first branch point 16. At a second branch point 16 downstream of the first branch point 16, the second optical fiber 14 is now cleaved again and routed out of the distribution cable 12 at the second branch point 16 to provide optical power to a second split network 20, thereby disrupting optical continuity of the second optical fiber 14 downstream of the second branch point 16. The signal returned by the second split network 20 is spliced back into first opticalAttorney Docket No.: HI24-133PCT fiber 14 which has been cleaved again at the second branch point 16 in a manner that provides continuity of the optical signal downstream of the second branch point 16 until the next branch point. In this manner, alternating segments of two optical fibers 14 are repeatedly and sequentially cleaved and then spliced to the tether fibers 46a and 46b at each branch point 16 of a series of branch points along the length of the distribution cable in a way that maintains optical continuity necessary to create upstream and downstream signal paths as needed to all the asymmetric tap couplers 22 within the series until the optical signal power for that series is exhausted. .

[0030] The reason that alternating segments of two optical distribution fibers 14 are preferred to support a series of branch points within a factory built cable assembly is that it provides means of cleaving one of the fibers slightly upstream of the branch point and cleaving the other fiber slightly downstream of the branch point is that the overlapping lengths of the two cleaved ends of the two optical fibers 14 make available sufficient excess fiber length or working fiber slack that can be withdrawn from the distribution cable and be extended to the splicing platform of a fusion slicer for splicing the distribution optical fibers 14 to the tether fibers 46a and 46b. Additionally, it is desirable to have some excess fiber length available after splicing in case a splice between one of fibers 14 of the distribution cable 12 and the first tether fiber 46a or second tether fiber 46b is a bad splice and has to be cut out and respliced. If the optical fiber providing the signal to the split network was the same optical fiber to which the optical signal was returned, then the cable technician would have less fiber slack with which to work when splicing the cleaved ends of the optical fiber 14 at the branch point to the optical fibers 46a and 46b of the tether.

[0031] FIGS. 2A-2E depict a first method for forming a branch point 16 in a distribution cable according to an exemplary embodiment.

[0032] Referring first to FIG. 2A, an embodiment of a distribution cable 12 is shown. The particular type of distribution cable 12 is not particularly limited, and any of a variety of different cable constructions can be used for the distribution cable 12. In general, the distribution cable 12 is an optical fiber cable comprising a cable jacket 26 defining at least one longitudinal bore 28 extending along a length of the distribution cable 12 between a first cable end 30 defined as the upstream end and a second cable end 34 defined as the downstream end, and a plurality of optical fibers 14 are disposed in the at least one longitudinal bore 28. In one or more embodiments, the optical fibers 14 may be arranged in subunits, such as buffer tubes or ribbons, and in one or more embodiments, the subunits mayAttorney Docket No.: HI24-133PCT be stranded around a strength member. The distribution cable 12 may further include other structures, such as an armor layer, binder layers, water blocking wraps or tapes, and / or strength elements, for example. Further, the distribution cable 12 may have a circular crosssection, an obround cross-section, or a cross-section of another curved or polygonal shape.

[0033] In the embodiment shown in FIG. 2A, the distribution cable 12 includes four optical fibers 14a-14d. A first optical fiber 14a, a second optical fiber 14b, and a fourth optical fiber 14d of the distribution cable 12 are designated to provide optical signal pathways between an Optical Line Terminal (OLT) at a hub, not shown, and the first end 30 of the distribution cable 12. A third optical fiber 14c of the distribution cable 12 is not designated to provide an optical signal pathway between an Optical Line Terminal (OLT) at a hub and the first end 30 of the distribution cable 12. Instead, third optical fiber 14c is designated to be used as a bridge fiber in an embodiment of FIGS. 2A-2E. In the following illustration, the fourth optical fiber 14d provides optical signal continuity from the first end 30 of the distribution cable 12 to the branch point 16. Shown in FIGS. 2A-2E are three suitable locations 32, 38 and 42 for the formation of at least one first fiber access window in the cable jacket 26 of distribution cable 12 to facilitate a variety of possible means of accessing optical fibers 14d, 14c, 14b and 14a. In one or more embodiments, the at least one fiber access window extends a length L along the longitudinal axis of the distribution cable 12. In one or more embodiments, the length L is in a range of 1 inch to 12 inches, for example.

[0034] By way of example, in one or more embodiments, the fourth optical fiber 14d is cleaved downstream of first fiber access window 32 at first cleave location 36, which disrupts downstream optical continuity along the fourth optical fiber 14d. In one or more embodiments, the first cleave location 36 is accessed by the formation of fiber access window 38 where the fourth optical fiber 14d is cleaved. In accordance with other aspects of the present disclosure, instead of forming fiber access window 38, the fourth optical fiber 14d is cleaved at location 36 using a tool, such as the tool shown in FIG. 5 of U.S. Patent No. 7,346,243, issued on March 18, 2008, the entire contents of which is incorporated herein by reference thereto. The tool can be inserted into the longitudinal bore 28 from the fiber access window 32 in the downstream direction toward cleave location 36. Once positioned within the longitudinal bore 28, the tool is configured to cleave the fourth optical fiber 14d from within the cable jacket 26. Use of a tool in this manner eliminates the need to cut an additional fiber access window 38 into cable jacket 26 to access the first cleave location 36.Attorney Docket No.: HI24-133PCTIn one or more embodiments, the first cleave location 36 is up to 10 inches downstream of the fiber access window 32.

[0035] Further, the third optical fiber 14c is cleaved upstream of fiber access window 32 at a second cleave location 40. In one or more embodiments, another optical fiber access window 42 may be formed in the cable jacket 26 to access the second cleave location 40 of the third optical fiber 14c. In one or more other embodiments, the third optical fiber 14c is cleaved at the second cleave location 40 using a tool as described above, thereby eliminating the need to cut additional fiber access window 42 into cable jacket 26 to access the second cleave location 40. In one or more embodiments, the second cleave location 40 is up to 10 inches upstream of fiber access window 32. In one or more embodiments, the first cleave location 36 is an equal distance downstream of fiber access window 32 as the second cleave location 40 is upstream of the window 32.

[0036] As can be seen in FIG. 2 A, the first optical fiber 14a and the second optical fiber 14b extend from the upstream end 30 of distribution cable 12 in a downstream direction beyond the branch point 16 without being cleaved. As such, optical continuity is maintained along the first optical fiber 14a and the second optical fiber 14b through this section of the distribution cable 12.

[0037] With reference now to FIG. 2B, the cleaved fiber end associated with the upstream portion of fourth optical fiber 14d is withdrawn from the at least one longitudinal bore 28 through fiber access window 32, and the cleaved end associated with the downstream portion of third optical fiber 14c is withdrawn from the window 32. Thus, cleaved ends of the optical fibers 14c, 14d are on the exterior of the cable jacket 26. For ease and clarity of illustration, the first optical fiber 14a and second optical fiber 14b are omitted from FIGS. 2B-2E.

[0038] As can be seen in FIG. 2B, by cleaving each of the third optical fiber 14c and the fourth optical fiber 14d at opposing distances from fiber access window 32, the third optical fiber 14c and the fourth optical fiber 14d have sufficient slack to extend to the platform of a fusion splicer proximal to fiber access window 32 for performing a splicing operation. As shown in FIG. 2B, slack from the third optical fiber 14c may be arranged into one or more slack loops 44 to facilitate making a 180° turn. Additionally, or alternatively, slack from the fourth optical fiber 14d may be arranged into one or more slack loops 44. The use of the term “loop” does not necessarily require the optical fiber to be wound 360° or inAttorney Docket No.: HI24-133PCT multiple windings, and instead, the optical fiber may be wound to a lesser degree, such as at least 180°. In one or more embodiments, the slack loops 44 may be stored in a mini tray for mechanical protection of fiber slack and to limit fiber bending to a desired minimum bend radius. The mini tray may be fabricated by a variety of means including but not limited to metal stamping, thermoforming, thermoplastic injection molding, thermoset molding or other molding techniques from any of a variety of suitable materials including Henkel Technomelt PA687.

[0039] Referring now to FIG. 2C, the cleaved ends of the fourth optical fiber 14d and the third optical fiber 14c are spliced to a first tether fiber 46a and a second tether fiber 46b, respectively, of a tether 18. In this way, the fourth optical fiber 14d and first tether fiber 46a of tether 18 constitute at least a portion of an optical signal path from the OLT 15 at the hub, through the first branch point and to an input of an asymmetric tap coupler 22 within a first split network 20, where the asymmetric tap coupler taps a portion of the input optical power for provision of optical broadband services to subscribers within first split network 20. The second tether fiber 46b of tether 18 constitutes at least a portion of an optical signal path between an output of an asymmetric tap coupler 22 within first split network 20 and second optical fiber 14c of distribution cable 12, thus providing a means to return untapped optical power from an output of asymmetric tap coupler 22 within first split network 20 so it can be used for the provision of optical broadband services to subscribers in another split network 20 connected through a second branch point 16 downstream of the first branch point 16.

[0040] Referring again to FIG. 2C, in one or more embodiments, the fourth optical fiber 14d and the third optical fiber 14c are fusion spliced at one or more locations 47 to the first tether fiber 46a and the second tether fiber 46b, respectively. In one or more embodiments, the splice is protected with a splice tube 48. While FIG. 2C depicts a single tether 18 comprising both the first tether fiber 46a and the second tether fiber 46b, the first tether fiber 46a and the second tether fiber 46b may alternatively be in separate tethers 18. Still further, the first tether fiber 46a and the second tether fiber 46b may initially be in a single tether 18 and later furcated into two separate tether legs, each containing a single tether fiber of the tether fibers 46a, 46b.

[0041] After splicing the optical fibers 14c, 14d to the tether fibers 46a, 46b, the branch point 16 may be covered with an overmold 50 as shown in FIG. 2D. In one or more embodiments, the overmold 50 is formed by direct application of a thermoplastic molding resin or a reactive thermosetting polymer mixture such as a two-part polyurethaneAttorney Docket No.: HI24-133PCT composition, for example. In one or more embodiments, the overmold 50 comprises one or molded components formed in a separate molding operation and subsequently applied as a covering over the branch point. In one or more embodiments, the overmold comprises a thermal heat shrink. In one or more embodiments, the overmold 50 comprises protective tapes. In one or more embodiments, the overmold 50 covers the window 32, the splice tube 48, and the end of the tether 18. If a mini -tray is provided for holding slack loops 44, then the overmold 50 may also cover the mini-tray positioned within or proximate to the window 32. If additional fiber access windows 38, 42 are formed to cleave or withdraw the third optical fiber 14c and fourth optical fiber 14d, then a single overmold 50 may be provided to encompass all of the windows 32, 38, 42, or separate overmolds 50 may be provided around each of the windows 32, 38, 42. Still further, one overmold 50 may cover two of the fiber access windows (e.g., windows 32, 38) and a second overmold 50 may cover the remaining window (e.g., window 42).

[0042] Because the fourth optical fiber 14d is cleaved and spliced into the first tether fiber 46a, the fourth optical fiber 14d downstream of the first branch point 16 no longer carries optical signal. However, the third optical fiber 14c, which is spliced to the second tether fiber 46b that returns the untapped optical power, now carries optical signal downstream of the branch point 16. As shown schematically in FIG. 2E, alternating lengths of the fourth optical fiber 14d and alternating lengths of third optical fiber 14c can be spliced together in a manner that can provide optical continuity between OLT 15 at the hub and a series of branch points 16a, 16b, 16c and 16d along the length of the distribution cable 12 Consistent with the depiction in FIGS. 2A-2D, a portion of fourth optical fiber 14d provides optical continuity between the upstream end of the distribution cable 12 and a first tether 18a extending from branch point 16a. A portion of the third optical fiber 14c provides optical continuity between first tether 18a at branch point 16a and a second tether 18b extending from a second branch point 16b downstream of the first branch point 16a. At a second branch point 16b, another portion of fourth optical fiber 14d provides optical continuity between the second tether 18b at second branch point 16b and a third tether 18c extending from a third branch point 16c. Likewise, another portion of the third optical fiber 14c maintains optical continuity between tether 18c extending from branch point 16c and tether 18d extending from branch point 16d. The methods for accessing, cleaving, withdrawing and splicing of the appropriate portions of optical fibers 14d and 14c to the tether fibers of tethers 18a and 18c at branch points 16a and 16c, respectively are the same as those shown in FIGS.Attorney Docket No.: HI24-133PCT2A-2C. The methods for accessing, cleaving, withdrawing and spicing the appropriate portions of optical fibers 14d and 14c to the tether fibers of tethers 18b and 18d at branch points 16b and 16d, respectively are substantially the same as those shown in FIGS. 2A-2C. with the exception that the cleave locations for fourth optical fibers 14d must be upstream of branch points 16b and 16d and the cleave locations for third optical fiber 14c must be downstream of branch points 16b and 16d. In practice this is necessary to provide needed fiber slack for splicing of optical fibers 14d and 14c at branch points 16b and 16d. Furthermore, it imposes a physical constraint against the possibility of withdrawing the wrong cleaved fiber ends of optical fibers 14d and 14c from longitudinal bore 28 since at each fiber access window only the intended cleaved fiber end of fibers 14d and 14c can be easily withdrawn.

[0043] Referring again to FIGS. 2A-2E and the above descriptions, it is noted that third optical fiber 14c at the first end 30 of distribution cable 12 is not designated to receive an optical signal from an Optical Line Terminal (OLT) at a hub. Instead, third optical fiber 14c is designated to be used as a bridge fiber in an embodiment of FIGS. 2A-2E. Therefore, by using fiber accessing and splicing methods and splicing configurations shown in FIGS. 2A-2E, the two fibers 14d, 14c only support the delivery of optical broadband services to one series of branch points along the length of distribution cable 12. It is apparent from FIGS. 2A-2D that the second optical fiber 14b and the first optical fiber 14a, depicted only in FIG. 2 A, extend continuously within the at least one longitudinal bore 28 from the first end 30 of distribution cable 12 downstream of the first series of branch points 16 without being cleaved. These optical fibers 14b and 14a maintain optical continuity to OLT 15 at the hub and are available for the formation of additional branch points downstream of the first series of branch points. In an embodiment, alternating lengths of third optical fiber 14c, when cleaved downstream of the first series of branch points 16, and second optical fiber 14b can be accessed, cleaved and spliced to additional tethers 18 at additional branch points to form a second series of branch points 16 downstream of the first series of branch points 16. Likewise, alternating lengths of third optical 14c, when cleaved downstream of the second series of branch points, and first optical fiber 14a can be accessed, cleaved and spliced to additional tethers 18 at additional branch points 16 to form a third series of branch points 16 downstream of the second series of branch points 16. These second and third series of branch points 16 may be formed in the same manner depicted in FIGS. 2B-2E and described above for the formation of the first series of branch points 16. It may be generalized that by usingAttorney Docket No.: HI24-133PCT the methods disclosed and depicted in the foregoing detailed description, a distributed tap network containing a number M of branch point series, each brant point series comprising multiple branch points, can be supported by M+l optical fibers 14 extending from distribution cable 12.

[0044] FIGS. 3A-3D depict a second method for forming a branch point 16 in a distribution cable 12 according to another exemplary embodiment. As will be understood from the following description, the method of FIGS. 3A-3D only requires one optical fiber 14 to form a branch point 16, and by extension, multiple branch points 16 within a series of branch points 16. More generally then, a distribution cable 12 containing M optical fibers 14 can support delivery of broadband services through a plurality of branch points 16 distributed across M series of branch points 16 along the length of a distribution cable 12. For this reason, distribution cable 12 need only comprise a single optical fiber, though the methods and resulting cable assemblies may most advantageously comprise more than one optical fiber.

[0045] Referring first to FIG. 3 A, the distribution cable 12 is shown with four optical fibers 14a-14d. In this embodiment, each of the optical fibers 14a-14d provides optical continuity for its respective optical signal over the length of the distribution cable 12 until the optical signal is exhausted. For the purposes of discussion, the method will be described in relation to the fourth optical fiber 14d.

[0046] As can be seen in FIG. 3A, an upstream fiber access window 52 and a downstream fiber access window 54 are formed in the cable jacket 26. Optionally, an additional central fiber access window 56 is formed between the upstream fiber access window 52 and the downstream fiber access window 54. The fourth optical fiber 14d is cleaved at cleave point 58 within the central fiber access window 56. Alternatively, no central fiber access window 56 is formed, and a tool, such as the tool described above in relation to FIG. 2A, is utilized to cleave the fourth optical fiber 14d at the cleave point 58. In one or more embodiments, each of the upstream fiber access window 52 and the downstream access window 54 has a length in a range from 1 inch to 12 inches. In one or more embodiments, the cleave point 58 is disposed a distance up to 10 inches from the respective upstream fiber access window 52 and the downstream fiber access window 54.

[0047] After the fourth optical fiber 14d is cleaved, an upstream cleaved end 60 of the fourth optical fiber 14d is withdrawn from the upstream fiber access window 52, and aAttorney Docket No.: HI24-133PCT downstream cleaved end 62 of the fourth optical fiber 14d is withdrawn from the downstream fiber access window 54 as shown in FIG. 3B. This provides sufficient working slack to make fusion splices to the fourth optical fiber 14d outside of the distribution cable 12.

[0048] Thus, as shown in FIG. 3C, two splices are made to connect the upstream cleaved end 60 and downstream cleaved end 62 of the fourth optical fiber 14d to the tether 18. In one or more embodiments, the upstream cleaved end 60 and / or the downstream cleaved end 62 may be wound into one or more slack loops 44, which as discussed above may be one or more 360° loops or a turn of at least 180°. Further, in one or more embodiments, the upstream cleaved end 60 is spliced to an extension section 64 of the first tether fiber 46a at a first splice 66. In one or more embodiments, the first splice 66 is protected with a first splice tube 68. In one or more embodiments, the extension section 64 of the first tether fiber 46a is created by cutting the first tether fiber 46a to a length longer than the second tether fiber 46b.

[0049] The downstream cleaved end 62 is spliced to the second tether fiber 46b of the tether 18 at a second splice 70. In one or more embodiments, the second splice 70 is protected with a second splice tube 72. Thus, the optical signal path between OLT 15 and the input of an asymmetric tap coupler 22 within split network 20 includes the upstream portion of fourth optical fiber 14d spliced to the tether 18 through the first tether fiber 46a. The optical signal pathway between an output of the asymmetric tap coupler 22 within split network 20 and the downstream portion of fourth optical fiber 14d re-entering distribution cable 12 includes second tether fiber 46b of tether 18 spliced to the downstream cleaved end of fourth optical fiber 14d. This provides a means of returning the untapped portion of optical signal from the asymmetric tap coupler 22 to the distribution cable 12 to support the delivery of optical broadband services from OLT 15 at the hub to subscribers within other split networks 20 by way of additional branch points 16 downstream of the first branch point and within the same series of branch points.

[0050] Finally, with respect to FIG. 3D, the splices 66, 70, fiber access windows 52, 54, 56, and end of the tether 18 are covered with one or more overmolds 50 as described above.

[0051] Advantageously, embodiments of the present disclosure provide a preengineered, factory-built branched cable assembly suitable for use in distributed tap networks. The branch points along the length of the distribution cable are formed by variousAttorney Docket No.: HI24-133PCT disclosed means which may be applied to a wide variety of distribution cable designs containing at least one optical fiber, including distribution cables with distribution fibers that are not easily accessible in the field by conventional mid-span access methods. According to disclosed methods and assemblies, optical signal pathways are established between one or two optical fibers of a distribution cable and the inputs and outputs of a series of asymmetric tap couplers within a distributed tap network. The present disclosed methods provide efficient use of distribution fibers and enhanced fiber management in terms of additional slack for ease of working and reworking fusion splices. Further, the disclosed construction allows for the violation of minimum fiber bend radii at branch points along the cable assembly. Additionally, the overmold 50 provides mechanical and environmental protection for the optical fibers at the branch point without the need for bulkier splice cabinets and enclosures.

[0052] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article "a" is intended to include one or more than one component or element and is not intended to be construed as meaning only one.

[0053] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosed embodiments. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the embodiments may occur to persons skilled in the art, the disclosed embodiments should be construed to include everything within the scope of the appended claims and their equivalents.

[0054] It will also be apparent to those skilled in the art that the disclosed methods and cable assemblies made thereby, whether claimed or not, are useful not only for broadband public networks, but may also be advantageously used to make cable assemblies useful in other applications such as, but not limited to, enterprise local area networks, data centers, or wireless access networks.

Claims

1. Attorney Docket No.: HI24-133PCTWhat is claimed is:

1. A cable assembly, comprising: a distribution cable comprising an upstream cable end, a downstream cable end, and a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable; a plurality of optical fibers disposed within the at least one longitudinal bore, the plurality of optical fibers comprising a first optical fiber and a second optical fiber; at least one first fiber access window formed through the cable jacket to provide access to the plurality of optical fibers disposed within the at least one longitudinal bore; at least one first tether comprising a first tether fiber and a second tether fiber, the at least one first tether spliced to the distribution cable to form a first branch point; wherein the first optical fiber is cleaved downstream of one of the at least one first fiber access window such that a cleaved end of the first optical fiber is withdrawn from downstream of one of the at least one first fiber access window and spliced to the first tether fiber outside of the at least one longitudinal bore; wherein the second optical fiber is cleaved upstream of one of the at least one first fiber access window such that a cleaved end of the second optical fiber is withdrawn from upstream of one of the at least one first fiber access window and spliced to the second tether fiber outside of the at least one longitudinal bore; wherein an upstream portion of the cleaved first optical fiber withdrawn from one of the at least one first fiber access window is configured to provide a portion of an optical signal path upstream of the first branch point; wherein a downstream portion of the cleaved second optical fiber withdrawn from one of the at least one first fiber access window is configured to provide a portion of an optical signal path downstream of the first branch point; and wherein at least one of the at least one first fiber access window, an end of the at least one first tether, the first branch point, and the cable jacket at the first branch point are covered by an overmold.

2. The cable assembly of claim 1, wherein at least one of the first optical fiber, the second optical fiber, the first tether fiber, or the second tether fiber is wound in at least oneAttorney Docket No.: HI24-133PCT slack loop, the at least one slack loop being disposed within or proximal to the first fiber access window and within the overmold.

3. The cable assembly of claim 1, further comprising: at least one second fiber access window formed through the cable jacket downstream of the at least one first fiber access window to provide access to the plurality of optical fibers disposed within the at least one longitudinal bore; at least one second tether comprising a third tether fiber and a fourth tether fiber, the at least one second tether spliced to, and extending from the distribution cable to form a second branch point; wherein the second optical fiber is cleaved downstream of one of the at least one second fiber access window, a cleaved end of the second optical fiber is withdrawn from downstream of one of the at least one second fiber access window and spliced to the third tether fiber outside of the at least one longitudinal bore; wherein the first optical fiber is cleaved upstream of one of the at least one second fiber access windows, a cleaved end of the first optical fiber is withdrawn from upstream of one of the at least one second fiber access windows and spliced to the fourth tether fiber outside of the at least one longitudinal bore; wherein the spliced portion of the second optical fiber withdrawn from the at least one second fiber access window is configured to provide a portion of an optical signal path upstream of the second branch point; wherein the spliced portion of the first optical fiber withdrawn from the at least one second fiber access window is configured to provide a portion of an optical signal path downstream of the second branch point; and wherein at least one of the second fiber access window, an end of the at least one second tether, and the cable jacket at the second branch point are covered by a second overmold.

4. The cable assembly of claim 1, wherein the at least one first tether comprises two tethers, wherein the first tether fiber is disposed in one of the two tethers, and wherein the second tether fiber is disposed in the other of the two tethers.Attorney Docket No.: HI24-133PCT5. The cable assembly of claim 1, wherein the overmold covers each of the at least one first fiber access windows.

6. The cable assembly of claim 1, wherein the splicing of the plurality of optical fibers is configured such that 2M optical fibers cooperate to provide M optical signal paths between a at least one branch point and the upstream end of the distribution cable.

7. The cable assembly of claim 1, wherein the splicing of the plurality of optical fibers is configured such that M+l optical fibers cooperate to provide M optical signal paths between at least one branch point and the upstream end of the distribution cable.

8. The cable assembly of claim 1, wherein the overmold is formed from at least one of a reactive polymer blend, a molten thermoplastic material, a pre-molded covering, a heat shrinkable material or a tape.

9. A method of forming a cable assembly, comprising: opening at least one first fiber access window through a cable jacket of a distribution cable to provide access to a plurality of optical fibers within at least one longitudinal bore defined by the cable jacket; cleaving a first optical fiber disposed within the at least one longitudinal bore downstream of one of the at least one first fiber access windows and cleaving a second optical fiber disposed within the at least one longitudinal bore upstream of one of the at least one first fiber access windows; withdrawing a cleaved end of the first optical fiber from the at least one longitudinal bore from downstream of the at least one first fiber access window and out of the at least one first fiber access window, withdrawing a cleaved end of the second optical fiber from the at least one longitudinal bore from upstream of the at least one first fiber access window and out of the at least one first fiber access window; forming a first branch point by splicing the withdrawn cleaved end of the first optical fiber to a first tether fiber and splicing the withdrawn cleaved end of the second optical fiber to a second tether fiber, the first tether fiber and the second tether fiber being disposed in at least one first tether; andAttorney Docket No.: HI24-133PCT covering the first branch point, the cable jacket at the first branch point, the at least one first fiber access window, and an end of the at least one first tether with an overmold; wherein the spliced portion of the first optical fiber withdrawn from the at least one first fiber access window is configured to provide a portion of an optical signal path upstream of the first branch point; and wherein the spliced portion of the second optical fiber withdrawn from the at least one second fiber access window is configured to provide a portion of an optical signal path downstream of the first branch point.

10. The method of claim 9, further comprising winding at least one of the first optical fiber or the second optical fiber to form at least one slack loop, the at least one slack loop being disposed within the overmold.

11. The method of claim 9, wherein cleaving the first optical fiber and cleaving the second optical fiber further comprises extending a tool into the at least one longitudinal bore from at least one of the first fiber access windows to cleave the first optical fiber and the second optical fiber.

12. The method of claim 9, further comprising opening a first fiber access window through the cable jacket at a longitudinal position where the first optical fiber is to be cleaved and opening a first fiber access window through the cable jacket at a longitudinal position where the second optical fiber is to be cleaved.

13. The method of claim 11, wherein the covering further comprises covering all the first fiber access windows with the overmold.

14. The method of claim 9, further comprising: opening at least one second fiber access window through the cable jacket of the distribution cable downstream of the first fiber access window to provide access to the plurality of optical fibers within the at least one longitudinal bore defined by the cable jacket; cleaving the second optical fiber disposed within the at least one longitudinal bore downstream of the at least one second fiber access window and cleaving the first optical fiberAttorney Docket No.: HI24-133PCT disposed within the at least one longitudinal bore upstream of the at least one second fiber access windows; withdrawing a cleaved end of the first optical fiber from the at least one longitudinal bore from upstream of the at least one second fiber access window and out of the at least one second access window, withdrawing a cleaved end of the second optical fiber from the at least one longitudinal bore from downstream of the at least one second fiber access window and out of the at least one second fiber access window; forming a second branch point by splicing the withdrawn cleaved end of the second optical fiber to a third tether fiber and splicing the withdrawn cleaved end of the first optical fiber to a fourth tether fiber, the third tether fiber and the fourth tether fiber being disposed in at least one second tether; and covering the second branch point, the cable jacket at the second branch point, the at least one second fiber access window, and an end of the at least one second tether with a second overmold; wherein the spliced portion of the second optical fiber withdrawn from the at least one second fiber access window is configured to provide a portion of an optical signal path upstream of the second branch point; and wherein the spliced portion of the first optical fiber withdrawn from the at least one second fiber access window is configured to provide a portion of an optical signal path downstream of the second branch point.

15. The method of claim 9, wherein covering the first branch point, the cable jacket at the first branch point, the at least one first fiber access window, and an end of the at least one first tether with an overmold comprises application of at least one of a reactive polymer blend, a molten thermoplastic material, a pre-molded covering, a heat shrinkable material or a tape.

16. A cable assembly, comprising: a distribution cable comprising a cable jacket defining at least one longitudinal bore extending along a longitudinal axis of the distribution cable; an optical fiber disposed within the at least one longitudinal bore; an upstream fiber access window formed through the cable jacket to provide access to the optical fiber within the at least one longitudinal bore;Attorney Docket No.: HI24-133PCT a downstream fiber access window formed through the cable jacket to provide access to the optical fiber within the at least one longitudinal bore; at least one tether comprising a first tether fiber and a second tether fiber, the at least one tether spliced to the distribution cable to form a branch point; wherein the optical fiber is cleaved at a location between the upstream access window and the downstream access window such that the optical fiber comprises an upstream cleaved end and a downstream cleaved end; wherein the upstream cleaved end of the optical fiber is withdrawn from the upstream access window and spliced to the first tether fiber; wherein the downstream cleaved end of the optical fiber is withdrawn from the downstream access window and spliced to the second tether fiber; and wherein the upstream access window, the downstream access window, the branch point, an end of the at least one tether, and the cable jacket at the branch point are covered by at least one overmold.

17. The cable assembly of claim 16, further comprising an additional fiber access window formed through the cable jacket, between the upstream access window and the downstream access window, the additional fiber access window being located at the location where the optical fiber is cleaved.

18. The cable assembly of claim 16, wherein at least one of the optical fibers, the first tether fiber, or the second tether fiber is wound in at least one slack loop, the at least one slack loop being disposed within the overmold.

19. The cable assembly of claim 16, wherein the at least one first tether comprises two tethers, wherein the first tether fiber is disposed in one of the two tethers, and wherein the second tether fiber is disposed in the other of the two tethers.

20. The cable assembly of claim 16, wherein the overmold is formed from at least one of a reactive polymer blend, a molten thermoplastic material, a pre-molded covering, a heat shrinkable material, or a tape.Attorney Docket No.: HI24-133PCT21. A method of forming a cable assembly, comprising: opening an upstream fiber access window through a cable jacket of a distribution cable to provide access to an optical fiber within at least one longitudinal bore defined by the cable jacket; opening a downstream fiber access window through the cable jacket of the distribution cable to provide access to the optical fiber within the at least one longitudinal bore defined by the cable jacket; cleaving the optical fiber at a location between the upstream access window and the downstream access window such that the optical fiber comprises an at least one upstream cleaved end and a at least one downstream cleaved end; withdrawing the cleaved end of the optical fiber from the upstream access window and withdrawing the downstream cleaved end of the optical fiber through the downstream access window; forming a branch point by splicing the upstream cleaved end of the optical fiber to a first tether fiber outside of the at least one longitudinal bore and splicing the downstream cleaved end to a second tether fiber outside of the at least one longitudinal bore, the first tether fiber and the second tether fiber being disposed in at least one tether; and covering the upstream access window, the downstream access window, an end of the at least one tether, the branch point and the cable jacket at the branch point with an overmold.

22. The method of claim 21, wherein cleaving the optical fiber further comprises extending a tool into the at least one longitudinal bore from the upstream access window or downstream access window to cleave the optical fiber downstream of the upstream access window or upstream of the downstream access window.

23. The method of claim 21, wherein prior to cleaving the optical fiber, the method further comprises forming an additional access window through the cable jacket, between the upstream access window and the downstream access window, and cleaving the optical fiber is at, or proximal to, the additional access window.

24. The method of claim 21, further comprising winding the first optical fiber in at least one slack loop, the at least one slack loop being disposed within the overmold.Attorney Docket No.: HI24-133PCT25. The method of claim 21, wherein covering the upstream access window, the downstream access window, an end of the at least one tether, the branch point and the cable jacket at the branch point with an overmold comprises application of at least one of a reactive polymer blend, a molten thermoplastic material, a pre-molded covering, a heat shrinkable material or a tape.

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