Preconnectorized Fiber Cable Assemblies with Strain-Relieved Strength Components
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Solution Overview
Problem
Existing fiber optic cable assemblies face challenges in spanning rugged outdoor environments while requiring flexible cables for routing and efficient slack storage, with a need for quick and reliable installation methods that protect optical fibers and manage bendability.
Innovation Solution
The development of preconnectorized fiber optic cable assemblies with a hardened connector on one end, featuring a subunit surrounded by an upjacketed portion, where tensile yarns and strength components are strain-relieved independently, allowing for adaptable cable management and termination options, including the use of either hardened or non-hardened connectors, and providing continuous strain-relief regardless of the upjacketed portion's presence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fiber optic cable uses a round cable structure with multiple layers of aramid strength members and jackets, then the cable has sufficient tensile strength and protection, but the cable becomes bulky and difficult to route into enclosures with limited space
Solution Approach 1:
The cable is divided into two distinct portions: a subunit portion containing the optical fiber and tensile yarns, and an upjacketed portion containing the optical fiber, tensile yarns, and strength components. This segmentation allows each portion to be optimized independently - the subunit can be made flexible for routing while the upjacketed portion provides structural strength and protection.
Solution Approach 2:
Different portions of the cable have different structural properties tailored to their specific functions. The subunit portion is designed for flexibility and bendability to navigate tight spaces and enclosures, while the upjacketed portion is designed with additional strength components for tensile protection and rugged outdoor environments. This local differentiation resolves the contradiction between overall strength and local flexibility.
2Device complexity
If strength members are cut flush with the stripped back jacket and not attached to the connector, then the cable structure is simple, but the strength members do not provide effective strain relief to the connector
Solution Approach 1:
The strength components in the upjacketed portion are pre-configured and positioned to engage with the connector before installation. The crimp body is designed with features that automatically capture and attach the strength components during the connector assembly process, ensuring proper strain relief is established in advance rather than requiring post-installation adjustment.
Solution Approach 2:
A crimp body serves as an intermediary component that bridges the optical fiber, tensile yarns, and strength components. The crimp body mechanically engages all these elements and attaches them to the connector, ensuring that forces are properly distributed and strain relief is effectively transmitted from the connector back through the strength components to the cable structure.
3Reliability
If the cable assembly uses a hardened connector with strain-relieved strength components, then the connector is protected and installation is reliable, but the footprint at the second end is larger than necessary
Solution Approach 1:
The cable assembly allows for dynamic configuration at the second end. The upjacketed portion can be stripped away when not needed for outdoor protection, leaving only the compact subunit portion with its own tensile yarns for indoor connector termination. This dynamic adaptability allows the assembly to maintain a small footprint indoors while providing full protection outdoors when the upjacketed portion is present.
4Reliability
If the cable assembly provides continuous strain-relief from hardened connector to other connector, then the optical fiber is fully protected, but the installation process becomes more complex
Solution Approach 1:
The crimp body is designed as a universal component that performs multiple functions: it secures the optical fiber, attaches the tensile yarns, and engages the strength components. This multi-functionality allows a single installation process to establish continuous strain relief across all cable portions and connectors, simplifying the overall installation procedure while maintaining comprehensive fiber protection.
Data Source
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AI summary
Fiber optic cable assemblies having a preconnectorized hardened connector on at least one end of a fiber optic cable that includes a subunit cable surrounded by an upjacketed portion having strength components and method for making are disclosed. The subunit cable has the optical fiber and a plurality of tensile yarns disposed within a subunit jacket. The hardened connector is attached to the optical fiber at a first end and strain-relieves at least some of the plurality of tensile yarns and the strength components. The cable assembly may also include a non-hardened connector on the second end of the optical fiber along with an optional pulling grip.