Thermoplastic Overmolded Fiber Cable Branching With Insert Ramp Support
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Solution Overview
Problem
Conventional molding materials for optical fiber distribution cables are expensive, difficult to obtain in large quantities, and have a narrow range of properties, limiting customization and efficiency.
Innovation Solution
A cable assembly with a thermoplastic overmold and insert is used, where the insert creates a gap between the distribution and branch cables, supported by a ramp surface to maintain optical element alignment, and the overmold is formed from a thermoplastic material comprising polyolefin and thermoplastic polyolefin elastomer, allowing low-pressure injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional molding materials are used to protect branch cables, then protection against environmental contamination is achieved, but the materials are expensive, difficult to obtain in large quantities, and have a narrow range of properties
Solution Approach 1:
The patent changes the material parameters by using thermoplastic materials (polyolefin and thermoplastic polyolefin elastomer) instead of conventional thermosetting molding materials. This enables standard injection molding processes, improving availability and reducing cost while maintaining protective functionality.
Solution Approach 2:
The patent employs composite material construction with a multi-layer cable structure including distribution cable, branch cable, and overmold layers. This composite approach allows optimization of each layer's properties to achieve both protection and manufacturability.
2Reliability
If conventional molding materials are used, then cable protection is provided, but customization and range of properties are limited
Solution Approach 1:
The patent enables extensive customization by using thermoplastic materials that can be molded into various configurations and properties. The material parameters (temperature, pressure, composition ratios) can be adjusted to create different overmold characteristics while maintaining protection.
Solution Approach 2:
The thermoplastic material system provides multi-functionality, serving both as protective overmold and as a customizable component that can be adapted to different cable configurations and environmental requirements through standard molding processes.
3Reliability
If the overmold is formed to protect the optical elements, then environmental protection is achieved, but sharp bends may occur that compromise optical signal integrity
Solution Approach 1:
The patent applies preliminary action by positioning the branch cable and optical elements within the mold cavity before injecting the thermoplastic overmold material. This pre-positioning ensures proper alignment and prevents sharp bends during the molding process.
Solution Approach 2:
The patent uses the mold cavity as an intermediary structure that constrains and guides the thermoplastic material flow around the optical elements, preventing direct contact that could cause bending while still providing environmental protection.
4Reliability
If high-pressure injection molding is used to form the overmold, then complete coverage is achieved, but optical elements may be displaced or bent
Solution Approach 1:
The patent performs preliminary positioning of the branch cable and optical elements in the mold cavity before injection. This pre-positioning creates a framework that maintains optical element stability even during complete overmold coverage at standard injection pressures.
Solution Approach 2:
The mold cavity serves as an intermediary constraint that controls thermoplastic material flow, enabling complete overmold coverage without requiring excessive pressure that would displace or bend the pre-positioned optical elements.
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 provides a cost-effective, easily sourced, and customizable protection against environmental contamination while maintaining optical signal integrity by preventing sharp bends and ensuring proper alignment during molding.
Implementation Method 1
A thermoplastic overmold is formed around the opening of the distribution cable, the end of the branch cable, at least a portion of the at least one optical element, and the insert
Data Source
AI summary
A cable assembly in which a distribution cable contains a plurality of optical elements and has an opening formed in the distribution cable. A branch cable has a bore extending along a length thereof, and an insert is positioned in the opening of the distribution cable. At least one optical element of the plurality of optical elements extends from the distribution cable through the opening and into the bore of the branch cable. A thermoplastic overmold is formed around the opening of the distribution cable, an end of the branch cable, at least a portion of the at least one optical element, and the insert. The insert creates a gap between the distribution cable and the branch cable, filled by the thermoplastic overmold, and the insert includes a ramp surface to support the optical element in a transition from the opening into the bore of the branch cable.