Leaf-Shaped Intermittent Bonding for Optical Fibre Ribbon Density
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Solution Overview
Problem
Conventional high fibre count optical fibre cables suffer from poor packing efficiency, leading to increased cable diameter, handling difficulties, and higher costs, as well as inefficiencies at junction points and manhole installations, due to their rigid structure and impractical linear scaling in manufacturing.
Innovation Solution
An intermittently bonded optical fibre ribbon with a leaf-like bonding pattern, where central fibres are fully bonded and surrounding fibres are partially bonded in a vein-like structure, providing flexibility and maintaining a flat structure while reducing the number of bonds along the length, thereby optimizing fibre density within a smaller space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional optical fibre ribbons are used with traditional bonding structures, then the fibres are fully bonded for structural stability, but the cable diameter increases and handling becomes difficult
Solution Approach 1:
The bonding structure is segmented into three distinct regions: a first bonding region for outer fibres, a second bonding region for inner fibres, and an unbonded central region. This segmentation allows different parts of the ribbon to have different bonding characteristics, providing structural stability where needed while maintaining flexibility in the center for easier handling and reduced cable diameter.
Solution Approach 2:
Different regions of the optical fibre ribbon are assigned different bonding qualities. The outer regions have full bonding for stability, the inner regions have partial bonding, and the central region has no bonding. This local differentiation optimizes both structural integrity and handling characteristics without requiring complete bonding across the entire ribbon.
2Ease of manufacture
If conventional optical fibre ribbons are used with rigid structures, then manufacturing is simplified, but packing efficiency is poor leading to increased cable diameter
Solution Approach 1:
The ribbon structure transitions from a rigid fully-bonded configuration to a dynamic partially-bonded structure with a leaf-like bonding pattern. This dynamic design allows the ribbon to collapse and expand, enabling tighter packing of fibres and higher fibre density while maintaining ease of manufacture through a systematic bonding approach.
Solution Approach 2:
The bonding pattern is arranged in a leaf-like configuration that extends in multiple dimensions across the ribbon width. This dimensional arrangement optimizes space utilization and fibre packing efficiency while keeping the manufacturing process relatively simple through repetitive bonding patterns.
3Quantity of substance
If conventional high fibre count cables are used, then fibre density is increased, but the cables become inefficient at junction points and manhole installation
Solution Approach 1:
The ribbon is segmented into bonded and unbonded regions, creating a flexible structure that can be easily installed at junction points and manholes. The unbonded central region allows the ribbon to be bent and positioned in confined spaces, while the bonded outer regions maintain fibre alignment and density during installation.
Solution Approach 2:
The bonding parameters are optimized to create a ribbon that maintains high fibre density while possessing sufficient flexibility for installation. The partial bonding in inner regions and complete unbonding in the center create parameter variations that balance density with installability at junction points and manholes.
4Strength
If conventional optical fibre ribbons are used with full bonding, then structural integrity is maintained, but the ribbons collapse when load or force is applied at centre
Solution Approach 1:
The bonding structure is segmented to leave the central region unbonded while bonding outer regions. This segmentation creates a structural configuration where the unbonded center can collapse under load, while the bonded outer regions maintain overall structural integrity and prevent complete disintegration of the ribbon.
Solution Approach 2:
Different local regions have different bonding qualities tailored to their functional requirements. The outer regions have full bonding for structural integrity, while the central region has no bonding to allow controlled collapse under load, optimizing both strength and collapse resistance.
Data Source
AI summary
An intermittently bonded optical fibre ribbon includes a plurality of optical fibres. The plurality of optical fibres is defined by at least two adjacent central optical fibers, a first plurality of optical fibers and a second plurality of fibers. The at least two adjacent central optical fibers are sandwiched between the first plurality of optical fibers and the second plurality of optical fibers. The at least two adjacent central optical fibers are fully bonded along length of the at least two central fibres. The first plurality of fibers and the second plurality of optical fibers are bonded partially along non-central length of the plurality of optical fibres.