Partially Bonded Optical Fiber Ribbon Random Matrix Application
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Solution Overview
Problem
Conventional partially bonded optical fiber ribbons face challenges in manufacturing speed, optical attenuation, and flexibility due to the need for precise bonding patterns, which result in reduced line speeds and increased manufacturing complexity.
Innovation Solution
A method of applying a bonding matrix material randomly or pseudo-randomly to a linear array of optical fibers to form a partially bonded optical fiber ribbon, allowing the ribbon to lay flat and be rolled into a circular shape without the need for precise control, using techniques such as spray nozzles or ink-jet printers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If precise bonding patterns are used to bond optical fibers intermittently, then the optical fiber ribbon can be folded or rolled into a cylindrical shape, but the manufacturing line speed is reduced to approximately half or less than half of fully bonded ribbons
Solution Approach 1:
The patent extracts the requirement for precise pattern control from the bonding process. Instead of applying bonding material in specific patterns, the patent applies bonding material randomly or pseudo-randomly across the optical fiber ribbon, eliminating the need for precision pattern application while still achieving the desired cylindrical folding capability.
Solution Approach 2:
The patent changes the parameter of bonding material application from controlled precise patterns to random or pseudo-random distribution. This parameter change allows the ribbon to maintain flexibility for cylindrical folding while enabling faster manufacturing speeds by eliminating complex pattern control requirements.
2Stability of the object's composition
If dense bonding patterns are used to allow the optical fiber ribbon to lay flat, then the ribbon structure is stable, but the ribbon becomes less flexible and induces higher optical attenuation
Solution Approach 1:
The patent applies bonding material with varying local density through random or pseudo-random distribution. Some areas have higher bonding density to provide stability for flat laying, while other areas have lower density to maintain flexibility and reduce optical attenuation. This local variation in bonding quality resolves the contradiction between stability and flexibility.
Solution Approach 2:
The patent uses a composite structure combining bonded and unbonded regions of the optical fiber ribbon. The random bonding creates a composite material system where bonded areas provide structural stability while unbonded areas maintain flexibility and minimize optical attenuation, achieving both flat laying stability and reduced optical loss.
3Ease of operation
If sparse bonding patterns are used to maintain flexibility and reduce optical attenuation, then the ribbon remains flexible, but the ribbon cannot lay substantially flat during slicing
Solution Approach 1:
The patent applies bonding material with varying local density through random or pseudo-random distribution. Some areas have higher bonding density to provide stability for flat laying during slicing operations, while other areas have lower density to maintain flexibility. This local variation in bonding quality resolves the contradiction between stability and flexibility.
4Manufacturing precision
If precise bonding patterns are applied in conventional manufacturing, then the optical fiber ribbon achieves the required bonding density, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The patent extracts the requirement for precise pattern control from the bonding process. Instead of applying bonding material in specific patterns requiring complex control systems, the patent applies bonding material randomly or pseudo-randomly, eliminating the need for precision pattern application equipment and reducing manufacturing process complexity.
Solution Approach 2:
The patent replaces complex precision pattern application systems with simpler random or pseudo-random bonding material application. This substitution uses less complex, more straightforward bonding processes that are easier to manufacture and maintain, reducing device complexity while achieving the required bonding density.
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 increases manufacturing line speeds, reduces optical attenuation, and enhances the flexibility of the ribbon structure while eliminating the need for precise pattern application, resulting in improved manufacturing efficiency and performance.
Implementation Method 1
applying a bonding matrix material randomly to at least a portion of at least two adjacent optical fibers
Data Source
AI summary
Embodiments of the invention include a method for making a partially bonded optical fiber ribbon. The method includes providing a linear array of optical fibers, and applying a bonding matrix material randomly to at least a portion of at least two adjacent optical fibers. The bonding matrix material is applied randomly to the adjacent optical fibers in such a way that the linear array of optical fibers forms a partially bonded optical fiber ribbon. The bonding matrix material applied randomly to the adjacent optical fibers is dense enough to allow the resulting partially bonded optical fiber ribbon to lay substantially flat. Also, the bonding matrix material applied randomly to the adjacent optical fibers is sparse enough to allow the resulting partially bonded optical fiber ribbon to be rolled into a substantially circular shape.