Rollable Optical Fiber Ribbon Connectorization for Dense Circular Cables
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Solution Overview
Problem
Conventional flat optical fiber ribbons face challenges in achieving high fiber packing density due to their rigidity, leading to empty space when cabled into circular structures, and the process of connectorization is inefficient for high-fiber-count applications.
Innovation Solution
The use of rollable optical fiber ribbons, which are partially bonded and can be rolled into a circular shape, combined with multi-fiber ferrules for termination, eliminating the need for fiber separation and manual organization, and enabling efficient connection to multi-channel devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional flat optical fiber ribbons are used, then the cable structure becomes rigid and easy to manufacture, but the fiber packing density decreases and empty space is created in circular cable structures
Solution Approach 1:
The optical fiber ribbon is designed to be dynamically configurable between flat and circular configurations. The ribbon can be inserted in a flat state for easy manufacturing and handling, then transformed into a circular configuration within the connector to achieve dense packing. This dynamic adaptability resolves the contradiction between manufacturing simplicity and packing density.
Solution Approach 2:
The invention transitions the ribbon from a two-dimensional flat configuration to a three-dimensional circular configuration within the connector. By utilizing the internal space of the connector in multiple dimensions, the ribbon achieves high-density circular packing while maintaining the simplicity of flat ribbon manufacturing and insertion.
2Ease of manufacture
If conventional flat optical fiber ribbons are grouped into rectangular stacks, then the manufacturing process is simple, but the rectangular stack does not fit efficiently into round circular cable structures
Solution Approach 1:
The ribbon maintains a simple flat configuration during manufacturing and insertion, then transforms into a circular configuration within the connector. This dynamic transformation allows the ribbon to be easily manufactured in a flat state while achieving efficient circular packing in the final assembled state, resolving the contradiction between manufacturing ease and packing density.
3Productivity
If manual fiber separation and organization is performed for connectorization, then the connection precision can be high, but the time and cost of connectorization increases significantly
Solution Approach 1:
The optical fibers are pre-arranged in a precise linear sequence within the flat ribbon during manufacturing. This preliminary organization maintains the correct fiber sequence and alignment throughout insertion and transformation. When the ribbon transforms to circular configuration within the connector, the pre-established linear arrangement ensures that fibers remain properly aligned and sequenced, eliminating the need for time-consuming manual reorganization while preserving alignment precision.
Solution Approach 2:
The invention changes the physical configuration parameter of the ribbon from flat to circular, but maintains the sequential ordering parameter of the fibers throughout the transformation. By preserving the fiber sequence parameter during the configuration change, the system achieves both high-speed automated connectorization and precise fiber alignment without requiring manual intervention.
4Quantity of substance
If rollable optical fiber ribbons are used, then the fiber packing density in circular cables increases, but the ribbon structure becomes more complex
Solution Approach 1:
The ribbon structure incorporates dynamic transformability between flat and circular configurations. The partial bonding pattern enables the ribbon to be flexible and rollable, allowing it to transform from a simple flat configuration during insertion to a dense circular configuration within the connector. This dynamic capability achieves high packing density without permanently complicating the ribbon structure.
Solution Approach 2:
The invention changes the physical configuration parameter of the ribbon from flat to circular by modifying the bonding pattern rather than the fundamental ribbon structure. The partial bonding allows the ribbon to assume different configurations (flat or circular) based on installation requirements, achieving high packing density while maintaining structural simplicity through parameter adjustment rather than structural complexity.
Data Source
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AI summary
Embodiments of the invention include a connectorized optical fiber cable. The connectorized optical fiber cable includes at least one multi-fiber unit tube and at least one rollable optical fiber ribbon comprising a plurality of optical fibers positioned within the multi-fiber unit tube. The plurality of optical fibers are rollable in such a way that a first portion of the at least one rollable optical fiber ribbon inside of the at least one multi-fiber unit tube is formed in a substantially circular shape and a second portion of the at least one rollable optical fiber ribbon extending from an end of the at least one multi-fiber unit tube is formed in a substantially flat shape. The connectorized optical fiber cable also includes a jacket surrounding the multi-fiber unit tube and a multi-fiber ferrule connected to an end of the second portion of the at least one rollable optical fiber ribbon.