Optical Cable Shield Layer Connection Method

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Solution Overview

Problem

Existing methods for connecting wires to the shield layer of optical cables, such as those used in submarine environments, are time-consuming, costly, and hazardous, often requiring heavy metals and extensive heating, and fail to effectively seal against water ingress.

Innovation Solution

A method involving a wire with conductors secured to an exposed shield layer using a clamp and thermoplastic sealants, where the wire is folded and sealed with a heat-shrinkable adhesive to establish an electrical connection and prevent leaks, utilizing materials non-hazardous to marine environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If heavy metal solders and chemical flux are used to connect wires to shield layer, then electrical connection is established, but assembly time increases and hazardous materials are introduced

Engineering Contradiction:

Improveelectrical connectionVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent removes hazardous materials (heavy metal solders and chemical flux) from the connection process entirely, replacing them with a mechanical crimping system that uses only corrosion-resistant metals and thermoplastic sealants, thereby eliminating the time-consuming preparation and cleanup associated with traditional soldering and flux application

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal and chemical processes of soldering with a purely mechanical crimping system, where a crimp member is mechanically deformed to secure the wire to the shield layer, eliminating the need for heating equipment and chemical flux application

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If heavy metal solders and extensive heating are used, then electrical connection is established, but cost increases and hazardous materials are introduced

Engineering Contradiction:

Improveelectrical connectionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs inexpensive corrosion-resistant metals (such as stainless steel or aluminum) for the crimp member instead of expensive heavy metal solders, and uses a single-use thermoplastic sealant that is cost-effective and eliminates the need for expensive flux materials and specialized heating equipment

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent eliminates expensive hazardous materials (heavy metal solders and chemical flux) from the process, replacing them with cost-effective alternatives that reduce both material costs and equipment requirements while maintaining connection reliability

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If existing connection processes are used, then electrical connection is made, but sealing against water ingress is insufficient

Engineering Contradiction:

Improveelectrical connectionVSAvoidwater ingress

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent combines the electrical connection function and the sealing function into a single integrated structure, where the crimp member simultaneously secures the wire electrically and the thermoplastic sealant simultaneously seals against water ingress, eliminating the need for separate sealing steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a composite sealing system combining corrosion-resistant metal (for structural integrity and electrical connection) with thermoplastic sealant (for water ingress protection), creating a composite structure that provides both electrical reliability and environmental sealing

Inventive Principle:

Principle #40Composite materials

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

This approach reduces assembly time, eliminates hazardous materials, and provides a cost-effective, watertight connection for both submarine and land-based optical cables, suitable for installation, repair, and factory assembly.

Implementation Method 1

utilizing materials non-hazardous to marine environments

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

sealed with a heat-shrinkable adhesive to establish an electrical connection and prevent leaks

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentEP1857848B1Optical cable shield layer connection

Publication Date: 2012.08.01 TYCO ELECTRONICS SUBSEA COMM LLC

Figure 1
Figure 2A~2D
Figure 2E~2H

AI summary

A method of connecting a conductor (232) of a wire (230) to a shield layer (206) of a shielded optical cable. A first portion of the conductor (232) is held against the shield layer (206) by a clamp (240) and the conductor is then folded back over the clamp (240) and embedded in sealant (250). A second portion of the conductor (232) is then captured by the clamp (240) and metallic tape (242) is wound around the clamp (240). Further sealant, possibly in the form of a heat shrink tube, is then provided between an exposed cable insulation layer (220) and an outer cable sheath (208). The connection may be made when coupling the optical cable to a device or another cable, for example, using a universal joint such as the Millennia® Joint available from Tyco Telecommunications (US) Inc. The wire (230) may provide a ground path from the shield layer (206) or a continuity path from the shield layer (206) to another optical cable.