Armored Cable Bonding Control via Particulate Matter

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Solution Overview

Problem

Conventional fiber optic cables face challenges in preventing water migration due to the formation of voids or channels between the armor and strength elements, which can lead to water propagation along the cable length.

Innovation Solution

The introduction of particulate matter on the exterior surface of the armor and filler material of a different composition than the covering, applied to the strength elements, inhibits the formation of voids and channels, while the filler material is used to embed the strength elements within the covering, facilitating easy separation during access procedures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If strength elements are placed adjacent to the armor, then cable strength is improved, but voids or channels form between the armor and strength elements that allow water migration

Engineering Contradiction:

Improvecable strengthVSAvoidwater migration

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

Filler material is introduced as an intermediary substance between the strength elements and the armor/corving interface. This filler material occupies the voids and channels that would otherwise allow water migration, while not interfering with the strength-bearing function of the strength elements adjacent to the armor.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If filler material is applied to strength elements, then water blocking is improved, but manufacturing complexity increases due to additional application steps

Engineering Contradiction:

Improvewater blockingVSAvoidmanufacturing process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The filler material is applied to the strength elements before the final covering is formed. This preliminary action ensures that the voids are filled before the covering process, integrating the water-blocking function into the manufacturing sequence without requiring separate post-processing steps.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If particulate matter is applied to the armor exterior surface, then bonding control is improved, but surface roughness increases which may affect covering application

Engineering Contradiction:

Improvebonding controlVSAvoidsurface roughness

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

Particulate matter is applied selectively to the exterior surface of the armor to control bonding characteristics in specific locations. The particulate matter creates localized bonding control at the armor-coring interface while the filler material subsequently fills the resulting surface irregularities to prevent water channels.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9140874B2Methods of controlling jacket bonding with cable armor and water blocking at strength members

Publication Date: 2015.09.22 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

A method of making an armored cable having a polymer covering where the bond between the armor and the covering is controlled by introducing particulate matter at the interface of the armor and covering. A filler material is applied to the exterior surfaces of the cable strength elements in order to inhibit the formation of voids in the polymer covering that would otherwise promote water migration along the cable.