High-Density Optical Fiber Cable With Tearable Thin-Film Lumens

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Solution Overview

Problem

Conventional optical fiber cables face challenges in increasing fiber density without increasing size, due to space considerations and the use of thick buffer tubes that hinder access and organization.

Innovation Solution

The use of thin membranes surrounding optical fibers in lumens, made from a polymer composition with a filler component at 30 wt % or less and specific surface area of at least 3 m2/g, allowing for high fiber density and hand-tearable lumens to maintain accessibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional buffer tubes are used to provide organization, then fiber organization is improved, but cable size increases and fiber density decreases

Engineering Contradiction:

Improvefiber organizationVSAvoidfiber density

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The patent replaces thick conventional buffer tubes with thin film coatings applied directly to individual optical fibers. These thin film coatings provide the necessary organization and protection while occupying minimal space, thereby maintaining high fiber density in the cable.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent extracts the organizational function from the bulk buffer tube structure and applies it at the individual fiber level through thin film coatings. This extraction allows the cable to achieve organization without the space-consuming bulk material of conventional buffer tubes.

Inventive Principle:

Principle #2Taking out (Extraction)

2Quantity of substance

If cable size is increased to carry more optical fibers, then fiber capacity is improved, but adaptability to existing ducts decreases

Engineering Contradiction:

Improvefiber capacityVSAvoidcompatibility with existing ducts

Core Design Contradiction:

Quantity of substanceVSAdaptability or versatility

Solution Approach 1:

The patent changes the physical parameters of the cable by using thin film coatings instead of thick buffer tubes, reducing the overall cable diameter. This parameter change allows the cable to fit within existing ducts while still carrying high fiber counts, thereby maintaining adaptability to existing infrastructure.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If membrane thickness is reduced to increase fiber density, then fiber density is improved, but mechanical strength and accessibility deteriorate

Engineering Contradiction:

Improvefiber densityVSAvoidmembrane strength

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent uses composite material structures for the thin film coatings, combining multiple materials or layers to achieve both thinness and sufficient mechanical strength. This composite approach allows the membrane to be thin enough for high fiber density while remaining strong enough to protect the fibers and facilitate handling.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250224579A1High fiber density optical fiber cable having a tearable lumen

Publication Date: 2025.07.10 CORNING RES & DEV CORP

AI summary

Provided are embodiments of a lumen. The lumen includes a plurality of optical fibers and a membrane surrounding the plurality of optical fibers. A thickness of the membrane is 50 μm or less. Further, the membrane is made from a polymer composition including a polymer component and a filler component, and the polymer composition includes 30 wt % or less of the filler component. The filler component has a specific surface area of at least 3 m2/g. The lumen may be incorporated into a high fiber density optical fiber cable. Also disclosed are embodiments of a method of forming the lumen and optical fiber cable.