Intermittently Bonded Optical Fiber Ribbon for Flexible Mass Splicing
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Solution Overview
Problem
Managing connections between optical fibers in fiber optic cable networks is difficult, and conventional optical fiber ribbons that are fully bonded along their length are inflexible, making them unsuitable for compact cable designs and efficient splicing.
Innovation Solution
An optical fiber ribbon with intermittently bonded subunits using a 'wet-on-wet' process, where the bonding material diffuses into the subunit coating, allowing for flexible configurations and efficient mass fusion splicing while maintaining cohesive strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If optical fibers are fully bonded together along the length of the ribbon, then structural strength and stability are improved, but flexibility and ease of splicing deteriorate
Solution Approach 1:
The bonding between optical fiber subunits is segmented into discrete intermittent bonds spaced along the length of the ribbon, rather than continuous bonding. This segmentation provides structural strength at bond locations while leaving gaps that allow the ribbon to be flexed and manipulated during splicing operations, directly resolving the contradiction between strength and ease of splicing.
Solution Approach 2:
The bonding characteristics vary locally along the length of the ribbon, with bonded regions providing strength and unbonded regions providing flexibility. This local differentiation of bonding quality allows the ribbon to exhibit both strong structural integrity where needed and operational flexibility where needed, resolving the contradiction between strength and ease of splicing.
2Productivity
If optical fibers are arranged in ribbons, then splicing efficiency is improved, but cable flexibility and compactness deteriorate
Solution Approach 1:
The ribbon structure uses intermittent bonding to create a segmented architecture where groups of fibers are bonded together in sections but separated in between. This allows the ribbon to maintain its organized structure for efficient splicing while enabling flexibility and compactness in the unbonded sections, resolving the contradiction between splicing efficiency and cable flexibility.
3Ease of manufacture
If bonding material is applied to cured subunit coating, then manufacturing simplicity is improved, but bond coherence and strength deteriorate
Solution Approach 1:
The subunit coating is applied in a wet, uncured state before the intermittent bonding material is applied. This preliminary action of keeping the coating uncured allows the bonding material to diffuse into and chemically integrate with the coating, creating strong cohesive bonds. This resolves the contradiction by sacrificing some manufacturing complexity (requiring precise timing) to achieve superior bond coherence.
Solution Approach 2:
The bonding process creates a composite structure where the intermittent bonding material and subunit coating materials interdiffuse and combine at the molecular level. This composite material approach, achieved by applying bonding material to uncured coating, produces bonds with superior coherence and strength compared to simple surface adhesion, resolving the contradiction between manufacturing simplicity and bond strength.
4Adaptability or versatility
If intermittent bonds are used instead of continuous bonding, then flexibility and compactness are improved, but manufacturing complexity deteriorates
Solution Approach 1:
The intermittent bonding is achieved through periodic application of bonding material at spaced intervals along the ribbon length, rather than continuous application. This periodic action creates the desired flexibility and compactness while using a relatively simple manufacturing approach that can be implemented with standard coating equipment, resolving the contradiction between flexibility and manufacturing complexity.
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 intermittently bonded optical fiber ribbon enables compact cable designs with higher fiber density and efficient splicing capabilities, facilitating easier installation and organization of optical fibers.
Implementation Method 1
the bonding material diffuses into the subunit coating
Data Source
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AI summary
Embodiments of the disclosure relate to an optical fiber ribbon. The optical fiber ribbon includes a plurality of subunits each comprising a subunit coating surrounding at least two optical fibers arranged adjacently to each other. The subunit coating is made of a first material. A plurality of bonds are intermittently formed between adjacent subunits of the plurality of subunits. The plurality of bonds are made of a second material. The optical fiber ribbon includes a diffusion zone at an interface between each of the plurality of bonds and the subunit coating of each adjacent subunit. Each diffusion zone has a gradient of the second material in the first material. Further, the intermittent bonds may include one or more saddle surfaces formed by intersecting convex and concave curvatures. A method of forming such optical fiber ribbons is also disclosed.