Optical Fiber Cable Intermittent Bonding Stability
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Solution Overview
Problem
Optical communication cables with stranded core elements require external radial binding elements for stability and accessibility, which complicates manufacturing and maintenance, and may lead to deformation and reduced crush resistance.
Innovation Solution
The implementation of intermittent bonding between adjacent core elements using laser welding, eliminating the need for external radial binding elements, allows for a stable SZ stranded core with controlled force distribution and improved accessibility, enabling easier separation and re-jacketing while maintaining the wrapped pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If external radial binding elements are used to stabilize stranded core elements, then structural stability is improved, but device complexity increases and accessibility deteriorates
Solution Approach 1:
The patent removes external radial binding elements (such as central strength members or binding tapes) from the cable structure. Instead, core elements are bonded directly to each other through laser welding, eliminating the need for separate binding components and reducing overall device complexity while maintaining structural stability.
Solution Approach 2:
The patent combines the functions of structural stability and core element bonding by directly welding adjacent core elements to each other. This merging eliminates the need for separate binding elements, as the core elements themselves provide both structural support and positional stability through direct bonding.
2Stability of the object's composition
If external radial binding elements are used to hold core elements, then structural stability is improved, but ease of operation deteriorates due to reduced accessibility
Solution Approach 1:
By removing external radial binding elements, the patent improves accessibility to core elements. Operators can directly access and manipulate core elements without first removing binding tapes or central strength members, simplifying maintenance and installation operations.
Solution Approach 2:
The patent uses discrete, segmented bonding sections rather than continuous binding. This segmentation allows core elements to be accessed and separated at unbonded sections, improving operational accessibility while maintaining stability at bonded sections.
3Stability of the object's composition
If continuous bonding of core elements is implemented, then structural stability is improved, but manufacturing precision deteriorates due to increased lay-length variability
Solution Approach 1:
The patent implements discrete, segmented bonding sections along the length of core elements rather than continuous bonding. This segmentation allows for controlled bonding intervals that maintain structural stability while accommodating variations in lay-length, improving manufacturing precision by preventing error accumulation over long continuous bonds.
Solution Approach 2:
The patent applies bonding partially along the length of core elements, using sufficient bonding sections to ensure stability without over-bonding. This partial action approach maintains structural integrity while allowing for manufacturing tolerances and reducing lay-length variability.
4Strength
If external binders and central strength members are used, then crush resistance is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of crush resistance and structural stability into the bonded core element structure itself. By directly bonding core elements together in a stable configuration, the structure inherently provides crush resistance without requiring separate binders or central strength members, reducing device complexity.
Solution Approach 2:
The patent removes external binders and central strength members from the cable construction. The bonded core element structure alone provides sufficient mechanical strength and crush resistance, eliminating unnecessary components and simplifying the overall device.
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
This approach enhances the stability and crush resistance of optical communication cables, reduces lay-length variability, and improves manufacturability by allowing for color-based identification and easier access to core elements, while eliminating the need for external binders and central strength members.
Implementation Method 1
Each adjacent pair of core elements is bonded together by a plurality of discrete laser welds joining outer surfaces of the adjacent core elements to each other
Data Source
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AI summary
An optical communication cable and related systems and methods are provided. The optical cable (10) includes a plurality of wrapped core elements (20,22), and the outer surfaces of adjacent wrapped core elements are joined together by discrete bond sections (34). The discrete bond sections (34) may be structures such as laser welds, ultrasonic welds, or adhesive material. The discrete bonds (34) hold the wrapped core elements together in the wrapped pattern, such as an SZ stranding pattern.