Fiber Optic Cable Assemblies with Interlocking Crimp Bands
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Solution Overview
Problem
Conventional fiber optic cable assemblies face issues with optical attenuation due to misalignment and lack of sufficient resistance to cable pull-off forces, leading to potential breakage and assembly destruction.
Innovation Solution
A fiber optic connector assembly featuring a crimp body with a crimp zone and a crimp band, where a sleeve is crimped to form a rib and indentation, mechanically interlocking with the crimp zone to secure the cable, providing enhanced strength and resistance to pull-off forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional crimping methods are used to attach cable to connector, then assembly is simple, but resistance to cable pull-off forces is insufficient
Solution Approach 1:
The crimp band is segmented into multiple compression areas (first, second, third compression areas) that can independently engage with corresponding features on the crimp body. This segmentation allows the crimp band to distribute pull-off forces across multiple engagement points, significantly increasing overall strength while maintaining a relatively simple band structure.
Solution Approach 2:
The crimp band features asymmetric geometry with ribs protruding in one direction and indentations positioned to engage with specific features on the crimp body. This asymmetric design creates mechanical interlocking that resists pull-off forces in the critical direction while keeping the band structure simple enough for practical manufacturing.
2Reliability
If conventional alignment methods are used, then assembly is straightforward, but optical attenuation occurs due to misalignment
Solution Approach 1:
The crimp band and crimp body are designed with pre-configured alignment features including ribs, indentations, and engagement surfaces that automatically guide and align the optical fibers during the crimping process. This preliminary alignment configuration ensures proper fiber alignment is achieved as a natural result of the mechanical assembly, improving optical signal strength without adding complex separate alignment mechanisms.
3Strength
If cable is firmly attached to connector, then pull-off resistance increases, but fiber alignment may be compromised
Solution Approach 1:
The crimping mechanism is segmented into multiple independent compression areas that can apply force at different locations and in different directions. This allows the assembly to achieve strong cable attachment through distributed compression while maintaining fiber alignment through carefully positioned compression zones that avoid distorting the fiber positions.
Solution Approach 2:
The crimp band acts as an intermediary element between the cable strength members and the crimp body. It transfers and distributes attachment forces through its multiple compression areas and mechanical interlocking features, achieving strong cable attachment while the controlled deformation of the crimp band itself protects the fiber alignment precision.
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 optical attenuation and significantly increases the resistance to cable pull-off forces, ensuring the integrity of the fiber optic cable assembly and allowing the use of less expensive fibrous strength elements like fiberglass.
Implementation Method 1
The tool is activated, crushing the sleeve into the crimp band form thus mechanically interlocking the sleeve to the crimp zone
Data Source
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AI summary
A fiber optic cable assembly includes a fiber optic cable with one or more optical fibers attached to a housing. The housing includes a connector housing for a connector, a furcation housing for a furcation, and a splice housing for a mid-span cable splice. The furcation housing and the splice housing include a crimp body. The crimp body has a compression area and at least one hoop about the compression area defining a crimp zone. A crimp band is arranged for engaging the crimp zone and including an indentation defining a compression surface and a rib defining a rib interior. The crimp band and the crimp body cooperate to grip the strength element and resist cable pull off forces. A method of making the fiber optic cable assembly is also disclosed.