Multi-Fiber Splice Protector for Compact High-Density Cable Assemblies
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Solution Overview
Problem
Conventional splice protectors for optical fibers are bulky, inflexible, and time-consuming to apply, limiting the practical attainment of higher fiber density in fiber optic modules and cable assemblies, especially for small diameter round cables.
Innovation Solution
A multi-fiber splice protector with a tubular strength member featuring a longitudinal opening and an inner cavity wider than the longitudinal opening, filled with a thermoplastic hotmelt material, allows fusion spliced optical fibers to be arranged in a non-one-dimensional array, providing a compact and bend-resistant protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional splice protectors are used, then mechanical protection is provided, but the device becomes bulky and inflexible
Solution Approach 1:
The patent transitions from conventional one-dimensional array fiber arrangement to a multi-dimensional compact arrangement within the splice protector. The inner cavity accommodates fibers in a folded or multi-layer configuration, reducing the overall volume while maintaining protection capabilities.
Solution Approach 2:
The splice protector employs a flexible tubular structure with a longitudinal opening that can be folded or bent to accommodate fibers in a compact manner. This flexible shell design replaces rigid bulkier protective structures, achieving both mechanical protection and reduced volume.
2Strength
If conventional splice protectors are used, then protection is provided, but application becomes time-consuming
Solution Approach 1:
The thermoplastic material is pre-positioned within the inner cavity of the splice protector before fiber insertion. This preliminary preparation allows for rapid fiber insertion and encapsulation without requiring post-installation adjustments or additional steps, significantly reducing application time.
Solution Approach 2:
The thermoplastic material undergoes a phase change from solid to molten state when heated, allowing easy fiber insertion, then solidifies to provide protection. This parameter change enables a simple, rapid application process where fibers are inserted into the molten material and automatically encapsulated upon cooling.
3Quantity of substance
If higher fiber density is attained, then space efficiency improves, but mechanical loads on splice increase
Solution Approach 1:
The flexible tubular splice protector with longitudinal opening distributes mechanical loads along its length and around its circumference, preventing concentration of forces on individual splices. The flexible material absorbs and dissipates mechanical stresses while maintaining compact fiber arrangement.
Solution Approach 2:
The combination of the tubular strength member material and thermoplastic material creates a composite protective structure that provides both mechanical strength and flexibility. This composite design handles mechanical loads effectively while accommodating high fiber density in a compact volume.
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 compact, flexible, and efficient protection of fusion splices, enhancing fiber density and reducing mechanical loads on the splice, while maintaining mechanical and optical integrity across a wide temperature range.
Implementation Method 1
heating a strength member as disclosed herein sufficiently to melt a thermoplastic hotmelt material arranged within the inner cavity of the strength member
Implementation Method 2
cooling the strength member and thermoplastic hotmelt material sufficiently to cause the thermoplastic hotmelt material to solidify around and encapsulate splice joints and stripped sections of the fusion spliced optical fibers
Data Source
Figure 1~2B
Figure 3~5
Figure 6~7
AI summary
A multi-fiber splice protector includes a strength member (80) having at least one wall (82) arranged in a tubular shape with a longitudinal opening (88) extending through the wall (82) to permit passage of a coated optical fiber (70A,70B) into an inner cavity (90), with a thermoplastic hotmelt material (94) arranged in the inner cavity (90). The longitudinal opening (88) has a first width between 1 and 2 times the diameter of one coated optical fiber (70A,70B), while the inner cavity (90) has a second width that is significantly greater than the first width to permit fusion spliced optical fibers (92) to be not exclusively arranged in a 1_D array in the inner cavity. A fiber optic cable assembly including a multi-fiber splice protector with thermoplastic hotmelt material (94) encapsulating fusion splice joints is further provided. Additionally provided is a method for forming a fiber optic cable assembly.