Fusion Spliced Fiber Optic Cable Assemblies with Compact Transition Housing
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Solution Overview
Problem
Existing fusion spliced optical fiber assemblies require large, rigid enclosures that occupy space and restrict flexibility due to the need for long protective sleeves between splice points, which can damage the fibers.
Innovation Solution
A fusion spliced cable assembly with a support structure that engages prepared fiber lengths in a compact transition area, allowing the fibers to be secured and protected without the need for long enclosures, using pre-formed grooves or cylindrical mandrels to bend and fold the fibers, and a transition housing to secure the spliced ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large splice trays, enclosure boxes or long rigid tubes are used to protect spliced optical fibers, then the splice area is protected from damage, but the assembly occupies considerable space and flexibility is restricted
Solution Approach 1:
The patent applies nesting by placing the spliced optical fibers inside a collapsible protective sleeve that can be compressed to a compact size. The sleeve contains the splice tray and fibers within a flexible outer structure, allowing the entire assembly to be nested or collapsed when not in use, thereby reducing the volume occupied while maintaining protection during installation and operation.
Solution Approach 2:
The patent employs a collapsible protective sleeve that can transition between expanded and compressed states. When expanded, the sleeve provides full protection for the splice; when collapsed, it reduces the assembly volume for convenient storage and handling. This dynamic structure resolves the contradiction between maintaining protection and reducing space occupation.
2Reliability
If large splice trays, enclosure boxes or long rigid tubes are used to protect spliced optical fibers, then the splice area is protected from damage, but cable flexibility is restricted
Solution Approach 1:
The patent replaces rigid protective enclosures with a flexible protective sleeve made of collapsible material. This flexible shell allows the cable assembly to bend and adapt to different routing configurations while still providing protection for the splice area. The flexibility of the sleeve maintains cable adaptability whereas traditional rigid tubes would restrict bending and positioning options.
3Reliability
If long rigid tubes are used to protect spliced optical fibers, then the fibers are protected from damage, but the distance between transition points must be large
Solution Approach 1:
The collapsible protective sleeve allows the spliced fibers to be nested or folded within a compact space. The sleeve can be compressed to accommodate the full length of prepared fiber from both cables within a short distance between transition points, eliminating the need for long protective tubes while maintaining fiber protection through the nested configuration.
Data Source
AI summary
The present disclosure describes fusion spliced cable assemblies. An assembly may include a first and a second fiber optic cable, where an end of at least a first optical fiber from the first fiber optic cable is fusion spliced together with an end of at least a second optical fiber from the second fiber optic cable, the first optical fiber having a first length of prepared fiber extending from the spliced end of the first optical fiber to a transition point of the first optical fiber, the second optical fiber having a second length of prepared fiber extending from the spliced end of the second optical fiber to a transition point of the second optical fiber, where the transition point of the first optical fiber is a distance from the transition point of the second optical fiber, and where a total length of prepared fiber is the sum of the first length of prepared fiber for the first optical fiber and the second length of prepared fiber for the second optical fiber; a support configured to engage at least a portion of the total length of prepared fiber such that the distance between the transition points of each optical fiber is less than the total length of prepared fiber of the first and second optical fibers; and a transition housing coupled to the first and second fiber optic cables and surrounding the support. Fusion spliced cable assembly breakout kits are also provided.