Molded Furcation Plug for Fiber Optic Cable Strain Relief
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Solution Overview
Problem
Conventional fiber optic cable furcation assemblies face challenges such as manufacturing complexity, high cost, and defects due to the use of epoxy, which is labor-intensive and difficult to automate, and can damage optical fibers during installation.
Innovation Solution
A molded fiber optic cable furcation assembly is created using an overmolding process that integrates a furcation plug and strain relief device, manufactured without epoxy, reducing the number of parts and simplifying the manufacturing process, allowing for automated production and protecting optical fibers from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy is used to secure optical fibers and strength members in conventional furcation assemblies, then bonding strength is achieved, but manufacturing complexity increases and automation becomes difficult
Solution Approach 1:
The patent removes epoxy and heat shrink components from the furcation assembly, replacing them with a molded furcation body that integrates all necessary functions. This extraction eliminates the complex multi-step assembly process while maintaining bonding strength through the molded structure itself.
Solution Approach 2:
The patent combines the furcation plug, strain relief device, and fiber securing functions into a single molded furcation body. This merging eliminates the need for separate epoxy application and heat shrink steps, simplifying manufacturing while achieving the same bonding and strain relief functions.
2Reliability
If epoxy is used in furcation assemblies, then fiber securing is achieved, but labor intensity increases and production efficiency decreases
Solution Approach 1:
The molded furcation body is self-securing through its integrated structure, eliminating the need for manual epoxy application and heat shrink operations. The fiber securing function is built into the molded structure, allowing for automated production while maintaining reliable fiber attachment.
3Reliability
If conventional furcation assemblies with epoxy are used, then fiber protection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive epoxy and heat shrink components with a single molded furcation body that can be produced more economically through injection molding. This single-component approach eliminates material costs and processing steps while maintaining fiber protection.
4Stability of the object's composition
If epoxy and heat shrink components are used in furcation assemblies, then structural integrity is maintained, but the number of parts increases
Solution Approach 1:
The patent merges the furcation plug, strain relief device, and fiber securing elements into a single molded furcation body. This integration maintains all necessary structural functions while reducing the assembly to one component, eliminating the need for multiple parts and assembly steps.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
Molded fiber optic cable furcation assemblies, and related fiber optic components, assemblies, and methods are disclosed. In one embodiment, an end portion of a fiber optic cable with a portion of a cable jacket removed to expose optical fibers and/or a cable strength member(s) therein and thereafter placing the cable into a mold for creating a molded furcation plug about the end portion of the fiber optic cable. The furcation plug may be overmolded about the end portion of the fiber optic cable. The molded furcation plug can be used to pull a fiber optic cable without damaging the optical fiber(s) disposed within the fiber optic cable. The molded furcation plug is advantageous since it manufactured with fewer parts, without epoxy, and/or without a labor intensive process that may be difficult to automate.