Pre-terminated Optical Distribution Assembly Furcation Design
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Solution Overview
Problem
Existing optical fiber cables face vulnerabilities and mechanical/environmental damage during branching due to openings in the protective jacket, which are costly and time-consuming to address in the field.
Innovation Solution
The optical fiber cable design includes furcation legs with a furcation plug and optical connectors, where splicing occurs closer to the connectors than the plug, reducing cable disruption and using a slidable jacket for exposure and protection, along with a short, rigid furcation plug for anchoring and pulling forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If branch lines are created by opening the cable jacket in the field, then fiber branching can be achieved, but the protective jacket creates vulnerabilities to mechanical and environmental damage
Solution Approach 1:
The patent pre-creates branch lines during cable manufacturing by incorporating furcation legs and splices at predetermined locations within the protective jacket, eliminating the need to open the jacket in the field. This preliminary action maintains jacket integrity while enabling branching capability.
Solution Approach 2:
The patent introduces furcation legs as intermediary structures that contain spliced fibers within the protective jacket. These legs act as mediators between the main cable and branch connections, allowing fiber access without compromising the jacket's protective function.
2Adaptability or versatility
If splicing is performed in the field to create branch lines, then fiber distribution can be achieved, but the process is costly, time-consuming, and less accurate
Solution Approach 1:
The patent performs all splicing operations during manufacturing at the factory, creating pre-terminated furcation legs with spliced fibers before cable installation. This preliminary splicing eliminates time-consuming field splicing operations and ensures higher accuracy through controlled manufacturing conditions.
Solution Approach 2:
The patent divides the cable into segmented sections with pre-spliced furcation legs at specific intervals. Each segment is independently prepared during manufacturing, allowing efficient installation without requiring field splicing operations for each branch point.
3Device complexity
If the splice location is closer to the furcation plug, then cable structure is simplified, but the connector and splice are more vulnerable to damage during pulling and installation
Solution Approach 1:
The patent positions the splice location along the longitudinal dimension of the furcation leg, closer to the connector end rather than the plug end. This dimensional repositioning places the vulnerable splice and connector regions away from the high-stress furcation plug area, reducing damage risk during cable pulling and installation while maintaining structural simplicity.
Data Source
AI summary
Embodiments of a furcated optical fiber cable are provided. A main distribution cable has optical fibers surrounded by a cable jacket. The optical fibers are divided into at least two furcation legs. A furcation plug is located at a transition point between the main distribution cable and the at least two furcation legs. The furcation plug surrounds at least a portion of the main distribution cable and each of the at least two furcation legs. Optical connectors are provided for each of the at least two furcation legs, and each connector includes optical fibers that are spliced at a splice location to the optical fibers of the connector's respective furcation leg. The splice location is closer to the connector than to the furcation plug. A method of furcating an optical fiber cable and a pulling configuration for the furcated optical fiber cable are also provided.