Optical Fiber Cable Compressed Core Manufacturing Method
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Solution Overview
Problem
Existing optical fiber cables face mechanical and optical degradation when binders like films or PET tapes are wound with high tension to reduce diameter, leading to increased pressure on contact points and subsequent attenuation.
Innovation Solution
A modified compression tool with a cylindrical cavity whose internal diameter gradually decreases is used to compress the core of the optical fiber cable, allowing for a smaller diameter without excessive pressure, accompanied by additional layers like aramid yarns and water-blocking tapes to maintain fiber packing density and minimize attenuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If binders and binding elements are wound with high tension to press the bundle of optical fiber ribbons, then the diameter of the optical fiber cable is reduced, but optical and mechanical degradation occurs in the optical fibers due to excessive pressure on contact points
Solution Approach 1:
The patent changes the parameter of compression application from high-tension point contact to low-tension distributed contact. The binder is wound with reduced tension (e.g., 0.5-2.0 N instead of high tension), and the compression force is distributed across multiple contact points along the cable length, transforming the compression parameter from intensive to extensive, thereby reducing local stress while maintaining overall cable compactness.
Solution Approach 2:
The patent introduces an intermediary structure (the binder wrapped in a specific configuration) that mediates between the need for cable compactness and the protection of optical fibers. The binder acts as a distributed compression element that spreads the compressive force uniformly across the fiber bundle, preventing direct high-stress contact between binding elements and individual fibers, thus protecting optical integrity while achieving diameter reduction.
2Weight of moving object
If the diameter of the optical fiber cable is reduced by packing a certain number of optical fiber ribbons, then cable weight is reduced and handling is easier, but optical attenuation increases due to pressure on contact points
Solution Approach 1:
The patent modifies the compression parameter from high local pressure to low distributed pressure. By winding the binder with controlled low tension and arranging it to contact the fiber bundle at multiple points, the pressure parameter is transformed from concentrated to distributed, enabling diameter and weight reduction without exceeding the optical fiber's pressure tolerance threshold, thus preventing attenuation increase.
Solution Approach 2:
The patent applies partial compression action rather than excessive compression. The binder is wound with sufficient tension to achieve the desired diameter reduction and cable compactness, but deliberately kept below the threshold that would cause optical degradation. This partial action approach achieves the necessary compactness for reduced weight and improved handling while staying within the safe operational limits of the optical fibers.
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
The solution effectively reduces the optical fiber cable's diameter while maintaining low optical attenuation (<0.30 dB/Km) and mechanical integrity, making it easier to handle and install without mechanical degradation.
Implementation Method 1
The compression tool has a cylindrical cavity, wherein an internal diameter of the cylindrical cavity gradually decreases from a first end to a second end of the compression tool. The core enters from the first end of the compression tool with a diameter d and exits from the second end with a diameter d-Δd
Implementation Method 2
The method includes bundling a plurality of optical transmission elements to form a core of the optical fiber cable, compressing the core and extruding a sheath around the compressed core
Data Source
AI summary
The present disclosure provides an optical fiber cable (200, 300) with a compressed core (206, 306) and manufacturing method thereof. The method includes bundling a plurality of optical transmission elements (202, 302) to form a core (206, 306) of the optical fiber cable (200, 300) and compressing the core (206, 306). The method further includes extruding a sheath (212, 312) around the compressed core (206, 306), wherein the core (206, 306) is compressed to a smaller diameter by a compression tool. The compression tool has a cylindrical cavity, wherein an internal diameter of the cylindrical cavity gradually decreases from a first end to a second end of the compression tool. The core enters from the first end of the compression tool with a diameter d and exits from the second end with a diameter d-Δd, such that Δd/d is greater than or equal to 0.05.