Intermittently Bonded Optical Fiber Ribbon for Compact Cable Splicing
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Solution Overview
Problem
Managing connections between optical fibers in fiber optic cable networks is difficult due to the challenges of identifying and organizing multiple fibers, leading to larger cable designs when they are arranged in ribbons.
Innovation Solution
An optical fiber ribbon with intermittently bonded subunits using a 'wet-on-wet' process, where bonds are formed between adjacent subunits, allowing for a diffusion zone with a gradient of materials, and featuring saddle-shaped surfaces for enhanced flexibility and cohesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If optical fibers are arranged in ribbons to allow multiple fibers to be fusion spliced together, then splicing efficiency is improved, but cable diameter increases and flexibility decreases
Solution Approach 1:
The ribbon is divided into multiple subunits, each containing a subset of optical fibers. These subunits can be independently handled and spliced, allowing the ribbon to be processed in smaller sections rather than as a single large unit, thus maintaining splicing efficiency while reducing the effective working diameter
Solution Approach 2:
The ribbon structure is made dynamically configurable through intermittent bonding - subunits can be separated along the ribbon length during installation and splicing operations, transforming the rigid large-diameter structure into a flexible, adaptable configuration that reduces the effective diameter during handling
2Productivity
If optical fibers are arranged in ribbons to allow multiple fibers to be fusion spliced together, then splicing efficiency is improved, but cable flexibility and ease of handling decrease
Solution Approach 1:
By segmenting the ribbon into subunits with intermittent bonding, the cable becomes easier to handle and flex during installation while still maintaining the capability for efficient multi-fiber splicing when subunits are aligned and bonded together at splice points
Solution Approach 2:
The intermittent bonding creates periodic bonding zones along the ribbon length, allowing the cable to be flexible in unbonded regions while maintaining structural integrity at bonded regions, thus improving ease of handling without sacrificing splicing efficiency
3Manufacturing precision
If subunit coating and bonds are cured separately, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The curing processes for subunit coating and bonds are merged into a single simultaneous curing step, eliminating the sequential time delay while maintaining precision through the wet-on-wet application method where bonds are applied to uncured coating, ensuring proper alignment and integration
4Ease of manufacture
If bonds are applied to cured subunit coating, then ease of manufacture is improved, but bond strength and cohesion decrease
Solution Approach 1:
The subunit coating is applied in an uncured state before bonds are applied, creating a receptive substrate that enhances bond adhesion. This preliminary preparation of the coating surface while still wet ensures stronger bonding without significantly complicating the manufacturing process
Solution Approach 2:
The wet-on-wet process creates a composite structure where bond material and coating material intermix at the interface, forming a diffusion zone that enhances the overall strength and cohesion of the bonded joint compared to bonding on cured, non-porous surfaces
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 enables flexible ribbons that can be rolled or folded, reducing cable diameter and increasing fiber density while maintaining ease of splicing and identification, thus optimizing cable design and installation efficiency.
Implementation Method 1
The second material diffuses into the first material creating a diffusion zone of the second material in the first material
Data Source
AI summary
Embodiments of the disclosure relate to an optical fiber ribbon. The optical fiber ribbon includes a plurality of subunits each comprising a subunit coating surrounding at least two optical fibers arranged adjacently to each other. The subunit coating is made of a first material. A plurality of bonds are intermittently formed between adjacent subunits of the plurality of subunits. The plurality of bonds are made of a second material. The optical fiber ribbon includes a diffusion zone at an interface between each of the plurality of bonds and the subunit coating of each adjacent subunit. Each diffusion zone has a gradient of the second material in the first material. Further, the intermittent bonds may include one or more saddle surfaces formed by intersecting convex and concave curvatures. A method of forming such optical fiber ribbons is also disclosed.