Multifibre Tight-Buffered Optical Cable for Compact Water Resistance
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Solution Overview
Problem
Conventional optical fiber cables face issues with water ingress, mechanical protection, and bulkiness when using multifiber connectors, particularly in last mile connectivity and indoor applications, and existing solutions do not adequately address these limitations.
Innovation Solution
An optical fiber cable design featuring a thermoplastic layer extruded over optical fibers, covering 50% to 95% of each fiber's surface area, with minimal empty space, and a sheath, using materials like nylon, PVC, or TPU, to form a compact, mechanically robust, and water-resistant unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If flat optical ribbons are used in cable for multifiber connectors, then space efficiency is improved, but cable handling and routing becomes difficult due to twisting and kinking
Solution Approach 1:
The patent transforms the flat ribbon structure into a round cable configuration by arranging optical fibers in a circular pattern around a central strength member. This curvature-based redesign eliminates the twisting and kinking issues inherent in flat ribbons while maintaining compact size through efficient spatial arrangement of fibers in a radial configuration.
Solution Approach 2:
The patent divides the cable into distinct functional segments: a central strength member, multiple optical fibers arranged radially, individual buffers surrounding each fiber, and an outer jacket. This segmentation allows each component to perform its specific function independently, improving overall cable flexibility and ease of handling while maintaining compact dimensions.
2Adaptability or versatility
If a flat ribbon is placed in a round cable, then multifiber connectivity is achieved, but the cable becomes large and bulky
Solution Approach 1:
The patent adopts a round cable geometry with optical fibers arranged in a radial pattern around a central strength member. This spherical arrangement allows for compact packing of multiple fibers (achieving multifiber connector compatibility) while minimizing the overall cable diameter, avoiding the bulky appearance that would result from forcing a flat ribbon into a round cable.
3Volume of moving object
If optical fibers are housed in sleeved micro-module with thickness less than 100 micrometres, then cable size is reduced, but protection from aerial environment conditions is insufficient
Solution Approach 1:
The patent employs an outer jacket made of protective material that surrounds all optical fibers and provides environmental protection. This flexible shell structure offers adequate protection against aerial environment conditions (moisture, UV, mechanical stress) while maintaining a compact cable size, overcoming the insufficient protection of ultra-thin sleeved micro-modules.
Solution Approach 2:
The patent implements a hierarchical protective structure with individual buffers surrounding each optical fiber, followed by an outer jacket enclosing all fibers. This segmented approach ensures that each fiber is individually protected while the collective arrangement within the outer jacket provides comprehensive environmental protection, achieving both compact size and high reliability.
4Stability of the object's composition
If gel locked micro-module is used, then fiber positioning is secured, but safety concerns prevent use in last mile home connectivity cables
Solution Approach 1:
The patent removes the gel locking mechanism from the cable design, extracting the harmful element that causes safety concerns. Instead, fiber positioning stability is achieved through mechanical means such as individual buffers and radial arrangement within the round cable structure, eliminating the need for gel while maintaining fiber stability.
5Reliability
If dry micro-module is used, then water penetration blocking is achieved, but fiber retraction under overhead environmental load causes fiber break
Solution Approach 1:
The patent incorporates individual buffers surrounding each optical fiber that provide mechanical cushioning and protection before external loads are applied. These buffers absorb and distribute mechanical stresses from overhead environmental loads, preventing direct transmission of force to the fragile optical fibers and avoiding fiber breakage while maintaining water penetration resistance.
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 design provides enhanced mechanical protection, resistance to water ingress, and maintains a compact size, improving handling and installation efficiency while maintaining high mechanical stability and reducing optical loss.
Implementation Method 1
a thermoplastic layer extruded over the plurality of optical fibers to form an optical unit
Data Source
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AI summary
Disclosed is an optical fiber cable (100, 200, 300) comprising: a plurality of optical fibers (102); a thermoplastic layer (104) extruded over the plurality of optical fibers (102) to form an optical unit (108) such that the thermoplastic layer (104) contacts a surface area in a range of 50% to 95% of each optical fiber of the plurality of optical fibers (102); and a sheath (106) that surrounds the optical unit (108).