Jacketed Cable Holes Control Armor Coupling

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Solution Overview

Problem

Fiber optic cables face challenges in controlling adhesion between the jacket and armor, leading to water migration and mechanical stress issues, which complicates field service operations and manufacturing processes.

Innovation Solution

A fiber optic cable design featuring a tape with holes between the jacket and armor, allowing controlled coupling through varying hole geometry and size to manage adhesion, friction, and contact, while incorporating superabsorbent materials to prevent water ingress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the jacket is coated with polymer or hot melt substance to increase adhesion to armor, then water blocking is improved, but field service operations become complicated and manufacturing consistency deteriorates

Engineering Contradiction:

Improvewater blockingVSAvoidfield service operations

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The continuous polymer coating is segmented into discrete adhesive beads or droplets spaced along the cable length. This segmentation allows water blocking at critical points while leaving gaps that facilitate jacket stripping during field service, resolving the contradiction between water protection and ease of maintenance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Adhesion properties are made non-uniform along the cable length by placing adhesive beads only at specific locations rather than applying continuous coating. This local concentration of adhesive provides sufficient water blocking where needed while maintaining ease of jacket removal in non-adhesive regions.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If the jacket is stripped too easily from the armor, then field service becomes easier, but water can migrate through gaps if the cable is damaged

Engineering Contradiction:

Improvejacket strippingVSAvoidwater blocking

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Rip cords are installed along the cable length to provide preliminary action for jacket removal. These cords allow technicians to easily initiate jacket stripping by pulling the cord, which then propagates along the cable to separate the jacket from the armor without requiring excessive force or specialized tools.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A separate rip cord element acts as an intermediary mechanism between the technician and the jacket-armor interface. The cord transfers the pulling force efficiently to initiate and propagate jacket removal, making the process easier while maintaining controlled adhesion through the bead pattern.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If continuous polymer coating is applied to ensure water blocking, then adhesion is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveadhesion consistencyVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of using expensive continuous coating applications, the invention employs inexpensive discrete adhesive beads that can be applied through simple dispensing mechanisms. These beads provide sufficient adhesion for water blocking without requiring complex coating equipment or precise control systems.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The adhesion strategy changes from continuous coating (high material quantity, complex application) to discrete beads (reduced material quantity, simple dispensing). This parameter change in the adhesion distribution pattern simplifies manufacturing while maintaining effective water blocking through concentrated adhesive points.

Inventive Principle:

Principle #35Parameter changes

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 protects optical fibers from mechanical stress and moisture, facilitating easy field service and economical manufacturing by regulating coupling between the jacket and armor, thereby enhancing the durability and reliability of fiber optic cables.

Implementation Method 1

incorporating superabsorbent materials to prevent water ingress

Methodology Applied

Scientific EffectSuperabsorption: Absorption (physical)

Data Source

PatentUS8577196B1Jacketed cable with controlled jacket coupling

Publication Date: 2013.11.05 SUPERIOR ESSEX INT INC

AI summary

A communication cable can comprise optical fibers protected by an armor, such as a corrugated metallic tube. An outer jacket can cover the armor to provide environmental protection. A tape located between the outer jacket and the armor can comprise holes, with the outer jacket extending into the holes, towards the armor. The tape can be wrapped around the armor to form a tube, for example. The holes can control coupling between the outer jacket and the armor, for example providing a desired level of friction, bonding, adhesion, adherence, fusion, and/or contact between the outer jacket and the armor.