APK Fiber-Optic Microcable Structure to Prevent Kinking
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Solution Overview
Problem
Existing fiber-optic microcables are stiff, prone to kinking or hockling when twisted or bent, and lack flexibility, strength, and hydrophobic properties, making them unsuitable for flexible undersea applications.
Innovation Solution
A microcable design featuring a core, cladding, buffer, and jacket, with a yarn layer of Vectran® or similar materials, and an outer jacket of Aliphatic Polyketone (APK), which provides flexibility, high strength, and hydrophobicity, preventing kinking and hockling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional e-glass outer jacket is used, then the microcable achieves high strength, but it becomes extremely stiff with a minimum bend radius of approximately 1.5 inches
Solution Approach 1:
The patent uses a composite construction with an e-glass reinforcement layer embedded in a polymeric outer jacket. This composite structure combines the high tensile strength of e-glass fibers with the flexibility of the polymer matrix, resolving the contradiction between strength and flexibility. The e-glass provides structural reinforcement while the polymer allows for easier bending and manipulation.
2Strength
If the microcable is made with traditional materials, then it achieves adequate strength, but it is prone to kinking or hockling when twisted or bent
Solution Approach 1:
The patent employs a polymeric outer jacket that acts as a flexible shell surrounding the e-glass reinforcement. This flexible protective layer prevents the microcable from kinking or hockling during twisting and bending operations, while still allowing the e-glass to provide the necessary tensile strength. The polymer jacket conforms to bends without creating sharp kinks that would damage the internal structure.
3Ease of operation
If the microcable diameter is reduced for small-diameter applications, then it achieves better flexibility, but it may compromise structural integrity
Solution Approach 1:
The patent uses a composite structure with e-glass reinforcement embedded in a polymeric matrix, which allows the microcable to maintain high structural integrity even at small diameters. The e-glass fibers provide strength-to-weight ratio advantages, enabling the cable to be both thin and strong. This composite approach allows the microcable to achieve diameters suitable for small-diameter applications while preserving structural integrity through the reinforcement layer.
Data Source
AI summary
A small diameter microcable is described that is flexible, elastic, high-strength, low-loss, hydrophobic and that does not kink or hockle when twisted or bent. In one example, the optical fiber microcable is a singlemode microcable with a diameter of 750 μm that includes: a core; a cladding; a buffer; a yarn around the buffer; and a jacket formed of Aliphatic Polyketone (APK) around the yarn. The yarn may be formed, e.g., of a liquid crystal polymer (LCP) or may be formed of other suitable materials. In another example, the optical fiber microcable is a singlemode microcable having a diameter of 360 μm that includes: a core; a cladding; a buffer around the cladding; and a jacket formed of APK around the buffer. Methods are also described for fabricating the microcables.