Optical Fiber Cable Core Design for Tension Management
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Solution Overview
Problem
Central core optical fiber cables without slotted rods face issues with transmission loss and manufacturability due to the tension from wrapping tapes, which can cause the core to be exposed and require increased material usage and thicker cables to prevent exposure.
Innovation Solution
An optical fiber cable design where the core part is formed by twisting multiple optical fiber units together, with a wrapping tape wound longitudinally and then twisted collectively with the core in the same direction, preventing excessive tension on the fibers and maintaining manufacturability by avoiding helical wrapping that could lead to exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wrapping tape is wound helically around the core part, then the core part is protected from exposure, but the optical fibers experience tension that increases transmission loss
Solution Approach 1:
The wrapping tape is divided into two functional sections: a longitudinal winding section that provides protection without tension, and a helical wrap part section that provides secure fastening. This segmentation allows each section to perform its specific function optimally without compromising the other.
Solution Approach 2:
The wrapping tape transitions from longitudinal winding (one-dimensional linear progression) to helical wrapping (two-dimensional spiral configuration). This dimensional change allows the tape to secure the core part effectively while the longitudinal section prevents fiber tension.
2Reliability
If the winding pitch of the linear body is reduced to prevent core exposure, then the core part is protected, but the linear speed at production must be lowered which deteriorates manufacturability
Solution Approach 1:
The securing function is divided between the wrapping tape's helical wrap part and the linear body. The wrap part provides the primary protection against core exposure, allowing the linear body to maintain a larger pitch and higher winding speed without compromising reliability.
3Reliability
If the wrapping margin of the wrap part is increased to prevent core exposure, then the core part is protected, but the cable becomes thicker and more material is used increasing cost
Solution Approach 1:
The wrap part is designed with dynamic helical winding that adapts to the core part's dimensions. This allows effective coverage and protection without requiring excessive material or creating an unnecessarily thick cable structure.
4Reliability
If the wrapping margin is increased to prevent core exposure, then the core part is protected, but it becomes harder to take out the optical fibers inside
Solution Approach 1:
The wrapping tape's longitudinal winding section and helical wrap part section can be separated during fiber extraction. The longitudinal section is easily unwound first, providing access to the core part while the wrap part remains in place to maintain cable integrity.
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 design suppresses transmission loss while allowing easy extraction of optical fibers and reduces material usage, maintaining excellent workability and preventing exposure during jacket removal.
Implementation Method 1
The core part is formed by an assembly of a plurality of the optical fiber units, each of the optical fiber units formed of optical fibers being twisted together
Implementation Method 2
a wrapping tape, which is longitudinally wound around an outer circumference of the core part
Data Source
Figure 1
Figure 2~3
Figure 4(a)~4(b)
AI summary
A jacket is provided to the outer circumference of a cable core, a rip cord, and a tension member. The cable core, the rip cord, and the tension member are collectively covered by the jacket. A wrapping tape is longitudinally placed on the outer circumference of a core part so as to be wound therearound. Thus, immediately after the wrapping tape is longitudinally placed and wound, a wrap thereof is formed so as to lie substantially straight in the axial direction of an optical fiber cable. In contrast, in an optical fiber cable, the cable core is obtained by combining and intertwining the core part and the wrapping tape. Because of this configuration, the wrap part of the wrapping tape 5 is helically disposed in the longitudinal direction.