Optical Cable With Direct Thermoplastic Jacket
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Solution Overview
Problem
Existing optical cables with reinforcement materials are not cost-effective and fail to maintain mechanical integrity when bent, particularly in applications where they are handled by children or subjected to frequent bending.
Innovation Solution
An optical cable design featuring a glass optical fiber with a cladding surrounded by a thermoplastic resin jacket, where the jacket directly contacts the optical fiber without a tension member, ensuring the fiber has the highest modulus of elasticity and a glass diameter of 30 μm to 200 μm, which allows for minimal distortion (6% or less) upon bending, thereby maintaining mechanical strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a tension member (such as aramid fiber) is used to reinforce the optical cable, then the tensile strength and mechanical integrity are improved, but the manufacturing cost increases and the cable structure becomes more complex
Solution Approach 1:
The patent removes the tension member (aramid fiber) from the cable structure, extracting the element that causes complexity and cost issues. The optical fiber itself is designed to bear the mechanical load through its glass diameter and modulus of elasticity, eliminating the need for separate reinforcement materials.
Solution Approach 2:
The optical fiber serves dual functions: transmitting optical signals and providing mechanical strength. By designing the glass optical fiber with appropriate diameter (30-200 μm) and high modulus of elasticity, it simultaneously performs communication and structural support roles, replacing the need for dedicated tension members.
2Strength
If the optical fiber glass diameter is increased to improve mechanical strength, then the tensile strength is improved, but the cable diameter increases and flexibility deteriorates
Solution Approach 1:
The patent optimizes the glass diameter parameter within a specific range (30-200 μm) to achieve the desired balance between strength and flexibility. This parameter optimization allows the fiber to have sufficient mechanical strength while maintaining appropriate cable flexibility for handling and installation.
Solution Approach 2:
The patent applies different material properties to different components: the glass optical fiber provides high modulus of elasticity for strength, while the thermoplastic resin jacket provides flexibility and protection. This local differentiation of material properties allows the overall cable to achieve both strength and flexibility without compromise.
3Reliability
If a tension member is used to protect the optical fiber during bending, then the mechanical integrity is improved, but the cable cost increases
Solution Approach 1:
The patent removes the tension member from the structure, eliminating the associated manufacturing costs. The optical fiber's own mechanical properties (glass diameter and modulus of elasticity) are sufficient to maintain integrity during bending operations without requiring additional protective elements.
Solution Approach 2:
The optical fiber serves itself by using its own structural properties to protect against bending damage. The glass fiber's inherent high modulus of elasticity allows it to withstand bending stresses without external reinforcement, making the system self-sufficient and cost-effective.
4Ease of operation
If the optical fiber glass diameter is reduced to improve flexibility, then the ease of handling is improved, but the distortion during bending increases and mechanical strength decreases
Solution Approach 1:
The patent establishes a minimum glass diameter threshold (30 μm) to ensure that the fiber maintains sufficient mechanical strength and controls distortion during bending. This parameter specification prevents the fiber from being too thin, which would cause excessive distortion and strength loss, while still allowing flexibility through the upper range of the specified diameter range.
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 optical cable achieves a predetermined mechanical characteristic without a tension member, preventing breakage during bending, securing tensile strength, and reducing transmission loss at low temperatures, while being inexpensive and easy to process for connector attachment.
Implementation Method 1
an optical fiber which includes a core made of glass and a cladding surrounding the core
Implementation Method 2
a jacket made of a thermoplastic resin, the jacket directly covering the coated optical fiber while in close contact therewith
Data Source
AI summary
An optical cable comprises a coated optical fiber having an optical fiber which includes a core made of glass and a cladding surrounding the core and a jacket made of a thermoplastic resin. The jacket is directly covering the coated optical fiber while in close contact therewith. In the optical cable, the optical fiber has the highest modulus of elasticity in materials constituting the optical cable, a glass diameter of the optical fiber is at least 30 μm but not more than 200 μm while being 5% or less of a cable diameter of the optical cable, and a distortion occurring in the optical fiber when bending the optical cable by 180° is 6% or less.