Fiber Optic Cable Dry Insert with Fold for Water Blocking

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Solution Overview

Problem

Conventional fiber optic cable designs that eliminate thixotropic materials fail to adequately protect optical waveguides from displacement, water migration, and temperature-induced viscosity changes, leading to messy cleaning processes and increased manufacturing costs.

Innovation Solution

A dry insert with a compressible layer and a water-swellable layer, connected by a fold, is used within the cable jacket's cavity to couple and cushion the optical waveguide, preventing displacement and water migration while maintaining optical performance across temperature variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If thixotropic material is used to protect optical waveguide, then adequate movement and coupling is achieved, but cleaning becomes messy and time-consuming

Engineering Contradiction:

Improvemovement and coupling of optical waveguideVSAvoidcleaning time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent removes thixotropic material from the cable assembly, extracting the problematic substance that causes cleaning issues while maintaining the protective function through alternative means (dry insert structure)

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a disposable dry insert that is discarded after serving its protective function, eliminating the need for cleaning operations and reducing time loss associated with removing and cleaning thixotropic materials

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of operation

If thixotropic material is used to protect optical waveguide, then adequate coupling is achieved, but viscosity changes cause dripping at high temperatures and attenuation at low temperatures

Engineering Contradiction:

Improvecoupling of optical waveguideVSAvoidoptical performance across temperature range

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent changes the physical state parameter from viscous thixotropic material to a dry, non-viscous insert material that does not exhibit temperature-dependent viscosity changes, thereby maintaining reliable optical performance across temperature extremes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite dry insert structure combining water-swellable material with compressible material, creating a multi-functional component that provides coupling, movement accommodation, and temperature stability without the viscosity problems of thixotropic materials

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If conventional water-swellable tapes are used to eliminate thixotropic material, then thixotropic material is removed, but adequate coupling and water blocking are not achieved

Engineering Contradiction:

Improveelimination of thixotropic materialVSAvoidcoupling and water blocking performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines water-swellable material with compressible material in a layered dry insert structure, creating a composite that simultaneously achieves water blocking, adequate coupling, and structural support - functions that conventional single-material tapes cannot provide

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different regions of the insert: water-swellable material for water blocking and compressible material for coupling and movement accommodation, with each region performing its specific function optimally

Inventive Principle:

Principle #3Local quality

4Ease of operation

If large numbers of water-swellable components are used to fill tube space, then adequate coupling is achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecoupling of optical fibersVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges multiple functions (water blocking, coupling, movement accommodation, and structural support) into a single integrated dry insert component, eliminating the need for multiple separate water-swellable components and reducing manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

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 dry insert effectively couples the optical waveguide to the cable jacket, preventing displacement and water migration, and maintains low optical attenuation across temperature changes without the need for messy cleaning or high manufacturing costs.

Implementation Method 1

a water-swellable layer disposed on the optical waveguide and extending along a length of the optical waveguide

Methodology Applied

Scientific EffectWater-swellable: Absorption (physical)

Implementation Method 2

a compressible layer disposed on the optical waveguide and extending along a length of the optical waveguide

Methodology Applied

Scientific EffectCompressible: Elasticity

Data Source

PatentUS7406233B2Fiber optic cable having a dry insert with a fold

Publication Date: 2008.07.29 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

A fiber optic cable includes at least one optical waveguide, at least one dry insert and a cable jacket. The at least one optical waveguide and at least one dry insert are at least partially disposed within a cavity of the cable jacket. The at least one dry insert has a first and second portion that are connected to one another. In one embodiment, at least one fold is present between the two portions.