Fiber Optic Cable Assembly Strain Relief Mechanism
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Solution Overview
Problem
The manufacture of fiber optic cable assemblies is cumbersome, particularly due to the time-consuming process of routing optical fibers through furcation tubes and attaching connectors, and existing assemblies are less robust as reinforcement components rely on glue for pull-out strength rather than structural reinforcement.
Innovation Solution
A fiber optic cable assembly design that includes leg assemblies, a trunk assembly, and a furcation assembly with spliced optical fibers, where the furcation assembly provides a robust mechanical linkage through fibrous and rigid strength members, allowing for pre-assembled and pre-terminated pigtails and connectors, and a fan-out structure with locks to secure these components, facilitating efficient deployment and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical fibers are individually routed through furcation tubes and connectors are manually attached, then the cable assembly can be manufactured, but the manufacturing process becomes time-consuming and cumbersome
Solution Approach 1:
The cable assembly is divided into separate modular components: pre-terminated pigtail cables with connectors, furcation tubes, and reinforcement components. These segments can be manufactured independently and assembled efficiently, eliminating the time-consuming process of individually routing fibers and manually attaching connectors during final assembly.
Solution Approach 2:
The pigtail cables are pre-terminated with connectors and pre-assembled with reinforcement components before final assembly. This preliminary preparation of components significantly reduces the time and complexity of the final cable assembly manufacturing process.
2Ease of manufacture
If reinforcement components are glued to the cable assembly, then the assembly can be constructed, but the pull-out strength depends on glue strength rather than structural reinforcement
Solution Approach 1:
The chemical bonding method (glue) is replaced with a mechanical bonding system. The reinforcement components feature integrated mechanical structures such as barbs, hooks, or interlocking geometries that physically engage with the furcation tubes and cable jackets, providing pull-out strength through mechanical resistance rather than adhesive bonding.
Solution Approach 2:
The reinforcement components combine multiple materials with complementary properties: rigid materials (such as metal or rigid plastic) for structural strength and resistance to pull-out forces, and potentially flexible materials for engagement with the cable assembly. This composite approach provides both structural reinforcement and secure mechanical attachment.
3Device complexity
If the cable assembly uses glued reinforcement components, then the assembly can be simplified, but the overall robustness of the cable assembly decreases
Solution Approach 1:
The mechanical reinforcement system replaces glued components with structurally integrated elements that provide both simplification and enhanced robustness. The mechanical interlocking structures ensure reliable attachment while maintaining assembly simplicity through standardized components and processes.
Data Source
Figure 1~1B
Figure 2~3
Figure 4~5
AI summary
A fiber optic cable assembly includes leg assemblies, a trunk assembly, a splice assembly, and a furcation assembly. Each leg assembly includes a jacket, an optical fiber, strength members, and a connector. The trunk assembly includes a jacket, optical fibers, strength members, and a multi-fiber connector. The splice assembly includes a tube supporting the optical fibers of the leg and trunk assemblies that are spliced together. The furcation assembly is attached to the splice assembly and includes a fan-out structure and first and second locks. The first lock binds the strength members of the leg assemblies to the furcation assembly, and the second lock binds the strength members of the trunk to the furcation assembly. As such, the furcation assembly provides a mechanical linkage between the trunk and leg assemblies to strain relieve the spliced optical fibers in the tube.