Pre-mold Assembly for Branched Optical Cable

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing optical fiber cable pre-molds, such as epoxy molding, are inefficient and costly, requiring long curing times and high material costs, and fail to adequately protect and stabilize tether splice regions from thermal and mechanical stresses during the application of overmolds.

Innovation Solution

A pre-mold assembly comprising a first shell, a second shell, and a clip that snap together around a distribution cable and tether cables, providing channels for each, and using injection-molded high-density polyethylene components to stabilize and insulate the tether splice region without adhesives or fasteners, preventing stress transfer from polyurethane overmold application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If epoxy molding is used to protect tether splice regions, then protection and stabilization are achieved, but assembly time increases due to long curing times and material costs increase

Engineering Contradiction:

Improveprotection and stabilization of tether splice regionVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The pre-mold assembly is divided into multiple modular components including a first shell, second shell, and clip that can be assembled separately and then combined. This segmentation allows for faster assembly without requiring long curing times associated with epoxy molding, while still providing adequate protection and stabilization of the tether splice region.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs injection-molded high-density polyethylene components instead of expensive epoxy materials. These molded parts provide the necessary protection and stabilization functions at lower material cost and without requiring lengthy curing processes, effectively replacing the epoxy molding approach with more efficient alternatives.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If epoxy molding is used to protect tether splice regions, then protection from thermal and mechanical stresses is achieved, but material costs increase

Engineering Contradiction:

Improveprotection from thermal and mechanical stressesVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention changes the material parameters by using high-density polyethylene with specific thermal and mechanical properties that provide adequate stress protection. The molded parts are designed with appropriate wall thicknesses and structural features to withstand thermal and mechanical stresses without requiring the expensive epoxy materials.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional epoxy molding is used, then tether splice region is protected, but the process is inefficient and costly

Engineering Contradiction:

Improveprotection of tether splice regionVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The distribution cable and tether cables are positioned in their final configurations before the shell components are assembled around them. This preliminary positioning ensures proper alignment and reduces assembly time, as the cables do not need to be repositioned after the mold is applied.

Inventive Principle:

Principle #10Preliminary action

4Loss of time

If injection-molded high-density polyethylene components are used instead of epoxy, then assembly time and material costs are reduced, but adequate protection and stabilization must be maintained

Engineering Contradiction:

Improveassembly timeVSAvoidprotection and stabilization

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The pre-mold assembly features curved and contoured surfaces that conform to the shape of the distribution cable and tether cables. This curved design provides uniform protection around the cables and helps distribute mechanical stresses evenly, maintaining reliability while using faster-setting polyethylene materials.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS11256055B2Pre-mold assembly for branched optical cable and related method

Publication Date: 2022.02.22 CORNING RES & DEV CORP

AI summary

Embodiments of a pre-mold assembly for a distribution cable having one or more tether cables are provided. The assembly includes a first shell having a first inner surface and a first outer surface, a second shell having a second inner surface and a second outer surface, and a clip that couples the first shell to the second shell. The clip has a first leg configured to engage the first outer surface of the first shell and a second leg configured to engage the second outer surface of the second shell. In an assembled state, the inner surfaces of the shells define a first channel configured to hold the distribution cable. Further, the inner surfaces of the shells define a second channel that originates within the shells. The second channel is angled relative to the first channel and is configured to hold the one or more tether cables.