Fiber Optic Cable Continuous Polymeric Sleeve Water-Blocking

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Solution Overview

Problem

Conventional water-swellable tapes and yarns used in fiber optic cables face issues such as powder migration during manufacturing, limited lengths, and the need for splicing, which complicates the production and performance of water-blocking systems.

Innovation Solution

A fiber optic cable design featuring a continuous polymeric sleeve surrounding a core assembly with integrated water-swellable material, which is extruded to form a closed loop and conform tightly to the core, reducing water migration by wicking and partitioning the water-swellable powder within the sleeve.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If water-swellable powder is carried on yarn or between nonwoven laminates, then water-blocking function is achieved, but powder migration occurs during cable bending or stretching

Engineering Contradiction:

Improvewater-blocking functionVSAvoidpowder position stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent uses a continuous polymeric sleeve as a flexible shell to contain the water-swellable powder. The sleeve maintains powder containment during cable bending and stretching while allowing the cable to flex, resolving the contradiction between maintaining water-blocking function and preventing powder migration.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent creates a composite structure by integrating water-swellable powder with a polymeric sleeve material. This composite approach combines the water-blocking capability of the powder with the structural integrity and flexibility of the polymeric sleeve, preventing powder migration while maintaining functionality.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional water-swellable tapes are used, then water-blocking is provided, but manufacturing complexity increases due to splicing requirements for longer lengths

Engineering Contradiction:

Improvewater-blockingVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a continuous polymeric sleeve that can be extruded in long lengths without interruption. This eliminates the need for splicing operations required by conventional tapes, reducing manufacturing complexity while maintaining continuous water-blocking functionality throughout the cable length.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent replaces the mechanical assembly process of splicing tape segments with a continuous extrusion process. The polymeric sleeve is formed in one continuous operation, substituting complex mechanical joining operations with a simpler, continuous forming process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If water-swellable powder is used without containment, then water-flow blocking is achieved, but powder dropping occurs on the manufacturing floor

Engineering Contradiction:

Improvewater-flow blockingVSAvoidmanufacturing cleanliness

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses the polymeric sleeve as a flexible containment shell that encloses the water-swellable powder throughout the extrusion and manufacturing process. This prevents powder from dropping on the manufacturing floor while maintaining full water-flow blocking capability when the powder swells upon water exposure.

Inventive Principle:

Principle #30Flexible shells and thin films

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 blocks water ingress and prevents slow migration, enhancing the reliability and manufacturing efficiency of fiber optic cables by ensuring continuous water-blocking without the need for additional tapes or yarns.

Implementation Method 1

The water-swellable material integrated with the polymeric sleeve may be partitioned to mitigate or even prevent slow migration of water through the cable

Methodology Applied

Scientific EffectWater-swellable material absorption: Absorption (physical)

Implementation Method 2

The polymeric sleeve draws down following extrusion and tightly conforms to the shape of the underlying core assembly

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS10712521B2Fiber optic cable with sleeve

Publication Date: 2020.07.14 CORNING OPTICAL COMMUNICATIONS LLC

AI summary

A fiber optic cable includes a core assembly including an optical fiber, a polymeric sleeve surrounding the core assembly, water-swellable material integrated with the polymeric sleeve, and a jacket surrounding the polymeric sleeve. The polymeric sleeve is continuous peripherally around the core assembly, forming a continuous closed loop when viewed in cross-section, and continuous lengthwise along a length of the cable.