Buffered Optical Fiber with Peelable Intermediate Layer
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Solution Overview
Problem
Existing buffered optical fibers face challenges in extracting long lengths without damaging the coating or causing signal attenuation due to strong bonding between the fiber and protective sheath, and existing solutions either use unsuitable materials like Teflon or require UV curing.
Innovation Solution
A buffered optical fiber structure with aramid mechanical reinforcing strands and a thermoplastic peelable intermediate material between the optical fiber and protective sheath, made from materials like polybutylene terephthalate or polyamide, allowing for longer extraction lengths without damaging the coating and maintaining signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tight buffer structure is used, then mechanical strength and stability are improved, but extraction length is limited to a few centimeters due to strong bonding
Solution Approach 1:
The patent introduces a buffer layer as an intermediary substance between the optical fiber and protective sheath. This buffer layer has controlled adhesive properties that allow the fiber to be extracted over long distances (meters rather than centimeters) while maintaining mechanical strength and stability during operation.
Solution Approach 2:
The patent modifies the bonding parameters between the protective sheath and optical fiber by introducing the buffer layer with specific adhesive characteristics. This changes the interaction from strong permanent bonding (tight buffer) to controlled temporary bonding that allows long-distance extraction while maintaining stability.
2Length of moving object
If semi-tight buffer with air gap is used, then extraction length increases to meters, but offset between fiber and sheath causes signal attenuation
Solution Approach 1:
The buffer layer serves as a mediator that maintains controlled contact between the protective sheath and optical fiber during extraction. This prevents the offset and misalignment that occurs with air gaps, thereby avoiding signal attenuation while still enabling long-distance extraction.
Solution Approach 2:
The patent changes the physical state between the fiber and sheath from complete separation (air gap) to controlled partial contact through the buffer layer. This maintains alignment and prevents signal attenuation while allowing meter-scale extraction lengths.
3Ease of operation
If Teflon intermediate layer is used, then extraction is improved, but fluorine content makes it unsuitable for building cabling
Solution Approach 1:
The patent changes the material composition of the buffer layer from fluorine-containing Teflon to fluorine-free alternatives such as polyethylene, polypropylene, or polyamide. These materials maintain the desired extraction properties while eliminating the harmful fluorine content for building cabling applications.
Solution Approach 2:
The patent employs composite material structures where the buffer layer is made from fluorine-free polymers that combine the necessary lubrication properties for easy extraction with the safety requirements for building installations. The composite structure maintains functional performance without harmful substances.
4Reliability
If cross-linked intermediate layer is used, then bonding control is improved, but UV curing process adds manufacturing complexity
Solution Approach 1:
The patent replaces the UV curing process (electromagnetic field-based) with thermal curing or simple cooling processes. The buffer layer materials are designed to cure or set through temperature control during extrusion, eliminating the need for UV lamps and complex curing equipment.
Solution Approach 2:
The patent changes the curing mechanism from photochemical (UV cross-linking) to thermal processes. The buffer layer materials are selected to achieve proper bonding control through temperature-dependent properties during the extrusion and cooling process, simplifying manufacturing.
Data Source
Figure 1~4
Figure 2~3
AI summary
The invention relates to a buffered optical fiber structure, to a telecommunications cable containing a plurality of such buffered optical fiber structures, and to a method of fabricating said buffered optical fiber structure, the buffered optical fiber structure (1) comprising: · an optical fiber (3) constituted by a fiber core (31), cladding (32) surrounding the fiber core (31), and a coating (33) surrounding the cladding (32); · a protective sheath (2) having a cavity (21) in which the optical fiber(3) is placed; the buffered optical fiber being characterized in that it comprises: · at least one mechanical reinforcing strand (4) extending in the cavity (21) along the optical fiber (3); and · a peelable intermediate material (5) in contact with the protective sheath (2) and encompassing the assembly formed by the optical fiber (3) and said at least one mechanical reinforcing strand (4).