Shapeable Strength Member Cable Design

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Solution Overview

Problem

Conventional optical fiber cables with predetermined shape strength members often result in increased cable diameters and cross-sectional areas, and may exhibit undesirable bends or spring back forces when twisted with optical fiber units, which are not optimized for specific cable designs.

Innovation Solution

Incorporating shapeable strength members made of high tensile strength fibers within a shapeable resin material that can be modified and fixed during cable formation, allowing for optimized shapes that do not revert to their original form, thereby reducing unwanted forces on adjacent fibers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional predetermined shape strength members are used, then cable construction is simplified, but cable diameter and cross-sectional area increase

Engineering Contradiction:

Improvecable construction simplicityVSAvoidcable cross-sectional area

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The strength member transitions from a rigid predetermined shape to a shapeable form through material property changes. The resin material changes its flow properties under heat or pressure, allowing it to be molded into optimized shapes that reduce cable cross-sectional area while maintaining structural support functions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The strength member is constructed as a composite of high tensile strength fibers embedded in a shapeable resin material. This composite structure combines the tensile strength of fibers with the formability of resin, enabling both cable construction flexibility and optimized geometric shapes that reduce overall cable dimensions.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If conventional predetermined shape strength members are used, then manufacturing process is simplified, but undesirable bends and spring back forces occur

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidfiber protection from unwanted forces

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The strength member is pre-formed with a generic shape that is later modified during cable construction. The shapeable resin allows the strength member to be molded into the precise shape needed for each cable design, preventing undesirable bends and spring back forces before the cable is completed, rather than dealing with these issues after assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The strength member transitions from a static predetermined shape to a dynamic shapeable form. The resin material's flow properties change under heat or pressure, allowing the strength member to be molded into optimized shapes that eliminate spring back forces and undesirable bends, improving fiber protection while maintaining manufacturing flexibility.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If conventional strength members with fixed shapes are used, then cable design flexibility is limited, but shape optimization during cable formation is prevented

Engineering Contradiction:

Improvecable design flexibilityVSAvoidstrength member shape optimization

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The strength member's shape is optimized through parameter changes in the resin material's physical state. By controlling temperature or pressure during cable formation, the resin's flow properties change, allowing it to be molded into shapes specifically optimized for each cable design configuration, thereby achieving both design flexibility and shape optimization.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The strength member is prepared in advance with shapeable properties, allowing it to be molded into optimized configurations during cable formation. This preliminary preparation of shapeability enables designers to optimize the strength member's geometry for specific cable applications without compromising manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

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 use of shapeable strength members enables the optimization of cable designs by maintaining the modified shape within a desired operating temperature range, reducing spring back forces, and improving anti-buckling support and thermal performance.

Implementation Method 1

A strength member may include a plurality of strength fibers positioned within a shapeable resin material. The shapeable resin material may allow a shape of the strength member to be molded during formation of a cable

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

The modified shape of the strength member may then be fixed such that it does not change within a desired operating temperature range of the cable

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS11454775B1Methods for forming cables with shapeable strength members

Publication Date: 2022.09.27 SUPERIOR ESSEX INT INC

AI summary

A method for forming a cable may include providing a strength member that includes a plurality of strength fibers positioned within a shapeable resin material. A shape of the strength member may be modified along its longitudinal length while twisting the strength member with one or more fiber optic components. The modified shape of the strength member may then be fixed within a desired operating temperature range of the cable, and a jacket may be formed around the strength member and the one or more optical fiber components.