Fiber Cable Assembly Encapsulation for Faster Pigtail Termination
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Solution Overview
Problem
The process of terminating and connecting high-fiber count cables in fiber optic networks is labor-intensive, time-consuming, and requires manual threading of fibers through furcation tubes, which is inefficient.
Innovation Solution
The use of cable assemblies with multiple mass fusion splices protected by encapsulation, allowing for coiling and featuring flexible conduits and protective sheaths to manage and protect the fibers, thereby simplifying the termination process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual threading of fibers through furcation tubes is used, then individual fiber termination can be achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent combines multiple individual fiber termination operations into a single mass fusion splice operation. Multiple fibers are spliced simultaneously to corresponding fibers in the cable assembly, eliminating the need for manual threading of each fiber through separate furcation tubes. This merging of operations directly addresses the contradiction by maintaining ease of termination while dramatically improving productivity through automated mass processing.
Solution Approach 2:
The patent performs preliminary actions by pre-positioning and protecting the mass fusion splices within an encapsulation structure before final cable assembly completion. The encapsulation is prepared in advance to receive and protect the spliced fibers, allowing the termination process to proceed more efficiently without requiring subsequent manual intervention for each fiber.
2Adaptability or versatility
If mass fusion splices are protected over a sufficiently short axial distance, then coiling of the cable assembly is enabled, but the encapsulation structure becomes more complex
Solution Approach 1:
The patent employs a flexible encapsulation structure that can accommodate the protected mass fusion splices within a compact axial distance. The encapsulation uses flexible materials and designs that allow the cable assembly to be coiled without damaging the protected splices, thereby enabling cable coiling capability while managing the complexity through material selection rather than structural complexity.
3Reliability
If flexible conduits are used to protect bare fibers after splicing, then fiber protection is improved, but the overall cable assembly complexity increases
Solution Approach 1:
The patent implements a nested structure where flexible conduits are integrated within the encapsulation assembly. The conduits are positioned and secured inside the encapsulation structure, allowing fiber protection to be provided without adding external complexity to the cable assembly. This nesting approach enables reliable fiber protection while maintaining a compact and manageable overall structure.
Data Source
AI summary
A multi-fiber cable assembly includes a pigtail segments spliced to a trunk segment using multiple mass fusion splices. The splices are disposed within an encapsulation at a common axial location. A flexible conduit extends from one end of the encapsulation to protect bare fibers of the trunk segment. A protective sheath extends from the opposite end of the encapsulation to protect the pigtail segments. The conduit and sheath are axially fixed to the encapsulation.