Branch Fiber Optic Cable Assembly with Pre-defined Segmented Jacket
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Solution Overview
Problem
The existing methods for connecting fiber optic cables are complex and costly due to the need for fusion-bonding in optical fiber distribution boxes, as the branching of optical fibers within the outer jacket makes it difficult to predict which fibers will be branched and how to manipulate their terminal ends.
Innovation Solution
A branch fiber optic cable assembly is created by providing a main fiber optic cable with pre-defined branching sites, where inner cords are cut and pulled out to form stub cables, which are then wrapped with protection sleeves, eliminating the need for on-site fusion-bonding and allowing direct connection to external equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical fibers are disposed within the outer jacket before branching, then the cable structure is protected and organized, but it becomes difficult to predict which fibers will be branched and how to manipulate their terminal ends
Solution Approach 1:
The outer jacket is divided into multiple sections with branching sites positioned at specific locations. Each branching site has a cut-out that exposes only the inner cords at that specific location, allowing operators to access and manipulate individual fibers at predetermined points without dealing with the entire bundle. This segmentation transforms the complex task of managing all fibers throughout the cable into manageable local operations at each branching site.
Solution Approach 2:
The outer jacket is pre-configured with branching sites and cut-outs during cable manufacturing, exposing inner cords at specific locations before the cable is installed. This preliminary action allows the cable structure itself to guide the branching operation, eliminating the need for operators to figure out which fibers to branch and how to access them during installation. The path for pulling fibers is predetermined by the jacket design.
2Reliability
If branched optical fibers are connected by fusion-bonding in an optical fiber distribution box, then reliable connections are achieved, but the operation becomes difficult and cost increases
Solution Approach 1:
The cable is pre-configured with branching sites that expose inner cords and create predetermined paths for fiber manipulation. This allows branching operations to be performed directly on the cable without requiring complex distribution boxes or fusion-bonding equipment during installation. The preliminary structuring of the cable makes the branching operation straightforward while maintaining connection reliability through proper fiber routing and protection.
Solution Approach 2:
The complex fusion-bonding process and distribution box infrastructure are extracted from the installation process. Instead of requiring operators to perform difficult fusion-bonding operations in distribution boxes, the cable design allows fibers to be pulled out and branched directly at predetermined sites along the cable itself, significantly simplifying the installation operation while maintaining connection integrity.
3Productivity
If fusion-bonding is performed in optical fiber junction boxes, then fiber connections are established, but the cost and time for installation increase
Solution Approach 1:
The cable manufacturing process preliminarily positions branching sites and cut-outs to expose inner cords at specific locations. This pre-preparation eliminates the need for time-consuming fusion-bonding operations during installation, allowing workers to simply pull and connect fibers at the predetermined branching sites. The preliminary structuring of the cable dramatically reduces installation time and associated labor costs.
Solution Approach 2:
The expensive and time-consuming fusion-bonding process is extracted from the installation workflow. The cable design enables branching to be performed through simple mechanical operations at predetermined sites, removing the need for specialized fusion equipment and skilled operators during installation, thereby reducing both installation cost and time.
Data Source
AI summary
A branch fiber optic cable assembly includes a main fiber optic cable and a plurality of stub cables. The main fiber optic cable has a plurality of branching sites which are spaced apart from each other along an axial direction of the main fiber optic cable. Each of the stub cables has a first end integrally connected to the main fiber optic cable at one of the branching sites, and a second end extending away from the main fiber optic cable. A method of making the branch fiber optic cable assembly is also disclosed.