Bonded Cable Subunits Around a Central Member for Easy Drop Separation
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Solution Overview
Problem
The process of splicing optical fiber cables is delicate and time-consuming, requiring precise placement and risking fiber cutting and environmental exposure, especially when subdividing large distribution cables at network nodes.
Innovation Solution
A method of preparing a bundled cable by winding subunits with thermoplastic jackets around a central member, using metal elements or hot melt adhesive to form bonds between subunits and the central member, allowing for easy separation at drop points and providing structural support without an outer jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cable splicing is used to subdivide distribution cables at network nodes, then precise fiber placement and connection are achieved, but the process becomes delicate and time-consuming with risks of fiber cutting and environmental exposure
Solution Approach 1:
The cable system is divided into multiple subunits (first subunit, second subunit, etc.) that can be independently handled and connected. Each subunit contains specific fibers that can be separately managed, allowing parallel processing and reducing overall splicing time while maintaining precision through standardized connection interfaces
Solution Approach 2:
Fibers are pre-organized and pre-positioned within subunits before the actual splicing operation. The subunits are prepared in advance with fibers already aligned and protected, so that when connection is needed, the delicate splicing process involves pre-prepared elements rather than raw fibers, reducing both time and risk
2Reliability
If traditional cable splicing is used to subdivide distribution cables, then fiber connections are established, but environmental exposure and risk of fiber cutting increase
Solution Approach 1:
Each subunit is enclosed in a protective jacket (first subunit jacket, second subunit jacket) that acts as a flexible shell protecting the internal fibers from environmental damage. These jackets maintain fiber protection during handling, transport, and installation, reducing exposure to harmful environmental factors while allowing the subunits to be easily connected and disconnected
Solution Approach 2:
By segmenting the cable into protected subunits with individual jackets, each fiber bundle is isolated and protected independently. This segmentation allows connections to be made between protected units rather than exposing individual fibers to the environment during the connection process, reducing cutting risks and environmental exposure
3Ease of operation
If subunits are wound around a central member without an outer jacket, then structural support is maintained and easy separation at drop points is enabled, but bonding strength between subunits and central member must be ensured
Solution Approach 1:
Different regions of the cable system have different bonding characteristics. At most locations, subunits are strongly bonded to the central member for structural support. At specific drop points, the bonding is designed to be releasable or weaker, allowing easy separation when needed. This local differentiation of bonding quality enables both strong support and easy separation
Solution Approach 2:
A bonding agent or intermediate layer is used between the subunit jackets and the central member to create controlled bonding. This intermediary material provides sufficient bonding strength for structural support while allowing for controlled separation at designated drop points where the bonding can be released without damaging the subunits or central member
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the splicing process by allowing subunits to be easily separated from the central member at drop points, reducing the risk of fiber damage and environmental exposure, while maintaining structural integrity and efficient data transmission.
Implementation Method 1
The metal element is then heated such that at least one of the first thermoplastic composition or the second thermoplastic composition forms bonds with the other of the first thermoplastic composition or the second thermoplastic composition
Implementation Method 2
A hot melt adhesive is applied to a central member. A plurality of subunits is wound around the central member. The hot melt adhesive forms a plurality of bonds between the plurality of subunits and the central member
Data Source
AI summary
Bundled cables and methods for preparing bundled cable are disclosed herein. In the method, a plurality of subunits is wound about a central member. The subunits include a subunit jacket made of a first thermoplastic composition and has a first outer surface, and the central member includes a central member jacket made of a second thermoplastic composition and has a second outer surface. A metal element is provided at an interface of the second outer surface and the first outer surface of the subunits. The metal element is heated such that at least one of the first thermoplastic composition or the second thermoplastic composition forms bonds with the other of the first thermoplastic composition or the second thermoplastic composition.