• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    fiber optic overhead cables. cable designs adapted for overhead installations are described, where the cable comprises a bundle of multiple-fiber, tight-plug sheath units with a thin, flexible film containment layer surrounding the bundle. the multiple fiber watertight buffer coating units have a malleable inner layer of acrylate that protects the fiber and minimizes a transfer of tension to the fiber; and a tough, tough acrylate outer layer that provides crush resistance. the thin film containment layer provides cable integrity with minimal added size and weight. the thin film containment layer coating is coated on an external buffer jacket.
    公开号:BR112014021671B1
    申请号:R112014021671-1
    申请日:2012-07-27
    公开日:2020-09-24
    发明作者:Carleton Gibbs；Mark G. Graveston；Jason Pedder；Peter A. Weimann
    申请人:Ofs Fitel, Llc；
    IPC主号:
    专利说明:

    [0001] [001] This application claims the benefit of provisional application 61 / 606,033, filed on March 2, 2012, which is incorporated here as a reference. Field of the Invention
    [0002] [002] This invention relates to fiber optic cables specially adapted for aerial installations. Background of the Invention (Parts of this background may or may not constitute prior art).
    [0003] [003] Overhead distribution cables are desirable for use in broadband communication networks from fiber to the home, from fiber to building installations, or from fiber to node. These are especially valuable in building these high-speed networks in small towns and rural areas, where communications services are provided most economically using an existing airfare right.
    [0004] [004] Traditional loose tube or center core optical cables are relatively bulky and heavy and can be difficult to install and handle in closures, junction boxes, etc., where the cable jacket may need to be removed for fiber routing and cables. Furthermore, if the cables are large and heavy, it may be necessary to reinforce or replace telephone poles to support the added weight of the optical distribution cable. Finally, the tubes of a loose tube cable or tapes in a central core tape cable can be difficult to route inside the wrappers. Loose buffer tubes tend to be rigid and difficult to flex, while tapes have preferential flexing which can make them difficult to route.
    [0005] [005] For loose tube cable designs, rigid thin-walled plastic tubes are often used. These rigid tubes, typically made of a polymer such as polybutylene terephthalate (PBT), are larger than the desired size of the cable units, and are prone to bending when manipulated. In some cases, it is necessary to remove the rigid buffer tube and route relatively fragile optical fibers into a more flexible tube. These practices add time and expense to the use of optical broadband distribution networks.
    [0006] [006] Another approach to reducing the size and weight of overhead cables is to use cables containing thin-walled, soft 'micro-sheath' tubes to bundle the fibers, as set out in US 6,334,015 and 7,082,241 from Sagem SA, bundle the optical fibers. Soft tubes may suit the desired compact size of the units, but these tubes typically contain a filler, which must be cleaned, and is a problem for installers. In addition, soft micro-tube material sometimes tends to adhere to the over-extruded cable sheath. When this occurs, and an installer tries to remove the cable sheath, the micro-sheath tube material can be inadvertently removed or torn, thereby exposing the fibers and making it more difficult to determine which fiber is which. Barrier tapes or other protective materials can be included in the cable sheath structure to help prevent damage to the micro-sheath tubes, but this adds cost and complexity to the cable.
    [0007] [007] An alternative solution that has been used in some European countries is, first, to install a microduct overhead, then later to install air-blown cable fiber units (often referred to as ABFUs), such as AccuBreeze ™ from OFS, or many similar commercially available products in the back pipeline. However, this is inefficient, as two installation steps are required. Also, there is a limit to the amount of fiber that can be installed in the conduit, as the current commercially available ABFUs are limited to 12 fiber counts.
    [0008] [008] Thus, there is a need for lightweight lightweight overhead cables with high fiber counts that can be easily installed in one operation. Statement of the Invention
    [0009] [009] We have designed a new cable structure, adapted for overhead installations, which uses multiple multiple fiber tight plug sheath units contained by a common thin film containment sheath. The multi-fiber tight-cap coating units comprise a double-layered optical fiber buffer coating of acrylate resin having an inner layer of malleable acrylate that protects the fiber and minimizes stress transfer to the fiber, and an outer layer rigid tough acrylate that provides crush resistance. The multiple fiber tight-cap lining units are bundled, and preferably twisted, and jacketed with the thin-film containment sheath. The cable is completed using an outer protective polymer jacket. Brief Description of the Drawing
    [0010] [010] Figure 1 is a schematic cross section of a tenacious multi-fiber plug unit used in the multi-fiber firm plug unit multiple cable of the invention;
    [0011] [011] figure 2 is a schematic cross section of a cable design of the invention showing three units of multiple fiber tight plug in a thin film containment sheath and an outer jacket; and
    [0012] [012] figure 3 is a schematic cross section of a larger fiber count cable similar to that in figure 2. Detailed Description
    [0013] [013] A multi-fiber tight buffer coating unit is shown in figure 1. In figure 1, a twelve-fiber modality is shown with twelve optical fibers 11, coated and embedded in a soft acrylate matrix 12. As is well known, a reference to an optical fiber means a glass fiber covered with a polymer protection cover. The elements in the figures are not drawn to scale. A relatively hard 13 acrylate coating layer is surrounding and coating the soft acrylate matrix. Together, the optical fibers, the acrylate matrix and the acrylate coating layer comprise a round, double-layered, fiber optic, firm plug coating. . In this embodiment, the multiple fiber firm buffer coating contains 12 optical fibers, but can contain 2 to 24 optical fibers. Multiple fiber firm buffer coatings with 4 to 12 optical fibers can be expected to be the most common in commercial practice. The multi-fiber, firm buffer coating unit shown in Figure 1 is described in more detail in U.S. Patent No. 7,720,338, which is incorporated herein by reference.
    [0014] [014] The double layer acrylate construction of the multiple fiber buffer coating, with the soft inner layer and the rigid outer layer, works to minimize the transfer of bending and crushing forces to the optical fibers, thus minimizing an attenuation signal. In some embodiments, the multi-fiber tight plug coating may have an oval cross section.
    [0015] [015] It is intended that the term matrix means a body with a cross section of matrix material in which other bodies (optical fibers) are embedded. A coating is intended to mean a layer that surrounds and contacts another body or layer.
    [0016] [016] The soft acrylate matrix and the hard acrylate coating are preferably UV curable acrylates. Other polymers can be replaced. UV-curable resins may contain flame retardants to improve the overall fire resistance of the cable. This can be a layer of polymer extruded over the fiber optic buffer coating, and can be useful in especially demanding applications, such as cables required to comply with the NFPA 262 Plenum fire standard. The flame retardant coating can be made from: PVC, low smoke PVC, PVDF, FEP, PTFE, composite fluoropolymer combinations, low smoke zero halogen polyolefin resins, flame retardant thermoplastic elastomers, and nylon flame retardants. Specific examples are DFDE-1638-NT EXP2 from Dow Chemical and Megolon 8142 from AlphaGary.
    [0017] [017] Overhead cables with high optical fiber count are produced, according to the invention, by bundling multiple multiple fiber tight plug sheath units into a single cable. A prior art approach to this is shown in Figure 2 of the patent referenced above. However, that cable design is improved by using the cable design described above. According to this invention, the multiple fiber tight buffer units are bundled in an extruded thin film containment sheath, shown at 24 in figure 2. The multiple fiber tight buffer coating units have a basic unit construction shown in figure 1, with multiple optical fibers 21 in a soft acrylate matrix 23 and in a more rigid acrylate coating 22. In this embodiment, the cable has three units of multiple fiber firm plug coating with the centers of the units in the corners of a triangle. In an implementation of the cable of figure 2, three units of 12 fibers of 1.4 mm are clad together in a cable of 36 fibers with a maximum diameter of 3.3 mm. Note that the thin film containment sheath 24 is malleable, in this case producing a cable shape that is approximately triangular. Malleable in the context of the invention is intended to mean that the shape of the thin-film containment sheath has some features or a feature that reflects the shape of the bundle of multiple-fiber tight-lining coating units. The term bundle is intended to mean a group of multiple fiber tight plug coating units assembled together, in most cases with at least some of the units in contact with another unit. In the context of the cable designs described here, a high fiber count cable contains at least twelve optical fibers, and typically more than 24.
    [0018] [018] The thin-film containment sheath can be of any suitable material which can be extruded into a thin layer with faults or holes, and can withstand the stress and temperature ranges of a typical air environment. Suitable resins for the thin-film containment sheath include LDPE, LLDPE, other polyethylenes, impact-modified polypropylenes, ethylene / vinyl acetate polymers, plasticized PVC and combinations thereof. Mineral fillers or other fillers can be added to the base resin to reduce shrinkage and thermal expansion, and to improve attenuation performance as a function of temperature.
    [0019] [019] In some installations, it may be beneficial to route the aerial cable through a portion of the interior of a building being serviced. In this case, the fillers can be used for flame retardant printing to the thin film containment sheath. In a preferred embodiment, the thin-film containment sheath is manufactured from Megolon 8110 UV BK, a non-halogen flame retardant resin commercially available from AlphaGary, Leominster, MA and Melton Mowbray, UK. As an alternative to a thin-film containment sheath, the multiple-fiber tight buffer coating units can be connected together with wires or threads. The thickness of the thin film layer is less than approximately 0.3 mm, preferably less than 0.15 mm.
    [0020] [020] To prevent unwanted incursions of water from traveling along the length of the cable, wires that swell in water or other material that swells in water, shown at 27 in figure 2, can be passed through the fiber tight lining units multiple. As is evident, in this cable project, these elements occupy a "free space", that is, they do not add up to the dimensions of the cable.
    [0021] [021] The aerial cable designs of the invention have at least three units. There can be more than three units, as desired. A cable with four multiple-fiber tight-cap sheath units is illustrated in figure 3. In a preferred embodiment of the cable shown in figure 3, four units of 12, 1.4mm fibers are sheathed together in a 48-fiber cable with a maximum diameter of 3.6 mm. In figure 3, the elements common to figures 2 and 3 have the same reference numbers. The multiple fiber tight buffer coating unit comprises elements 31 to 33. This embodiment shows five strands that can swell in water 37.
    [0022] [022] The combination of the multiple fiber tight buffer coating units with the extruded thin film containment sheath produces a general cable that is lighter and smaller than prior art designs. This result is partly due to the elimination of the reinforcement wire layer that is used in some prior art aerial cable designs. The reinforcement wire layer complicates the manufacture of the overhead cable and adds to the expense.
    [0023] [023] With reference again to figures 2 and 3, an external polymer cable jacket 25 is formed around the thin-film containment sheath. The cable jacket thickness can be, for example, 10 to 20 mils (254 to 508 μm). Suitable cable jacket polymers are PVC, PVDF, FEP, PTFE, compound fluoropolymer combinations. The cable jacket may contain steel or fiberglass resistance members, 28, or other suitable cable reinforcement.
    [0024] [024] An advantage of using UV cured acrylates in the double layer acrylate buffer coating is that the cabling operation used for applying UV cured coatings is fast and cost-effective. Double-layer acrylate coatings can be applied in tandem or simultaneously (using a two-compartment and double-matrix applicator). Other transparent cover materials, such as substituted alkyl silicones and silsesquioxanes, aliphatic polyacrylates, polymethacrylates and vinyl ethers have also been used as UV cured coatings. See, for example, S. A. Shama, E. S. Poklacki, J. M. Zimmerman, "Ultraviolet-curable cationic vinyl ether polyurethane coating compositions", U.S. Patent No. 4,956,198 (1990); S. C. Lapin, A. C. Levy, "Vinyl ether based optical fiber coatings", U.S. Patent No. 5,139,872 (1992); P. J. Shustack, "Ultraviolet radiation-curable coatings for optical fibers", U.S. Patent No. 5,352,712 (1994). The coating technology using UV curable materials is well developed. Covers using visible light for curing, that is, light in the range 400 nm to 600 nm can also be used. The preferred cover materials are acrylates or urethane acrylates, with a UV photoinitiator added.
    [0025] [025] Inner and outer layer materials can be characterized in several ways. From the general description above, it is evident that the module of the inner layer must be smaller than the module of the outer layer. Using the measurement method of the ASTM D882 standard, the recommended tensile modulus for the inner layer is in the range of 0.1 to 50 MPa and, preferably, from 0.5 to 10 MPa. A suitable range for the outer layer is from 100 MPa to 2000 MPa, and preferably from 200 MPa to 1000 MPa.
    [0026] [026] Layer materials can also be characterized using glass transition temperatures. It is recommended that the Tg of the inner layer is less than 20 ° C, and the Tg of the outer layer is greater than 40 ° C. For the purposes of this description, the glass transition temperature, Tg, is the point in the middle of the transition curve.
    [0027] [027] The individual optical fibers in the multiple fiber tight buffer units can be color coded to assist in the identification and organization of the optical fibers for connection. Multi-fiber firm buffer units can also be color-coded to provide additional assistance in organizing optical fibers.
    [0028] [028] The compact size of the fiber optic plug sheath allows for the manufacture of smaller cables than typically found in competing cable designs. Prior art overhead cables or ABFU / conduit systems typically have up to 12 fibers in a 6 mm diameter conduit. However, the overhead cable exposed as an embodiment of the invention is capable of holding 36 or 48 fibers in a cable of 7 mm in diameter. Therefore, the inventive cable has a much higher fiber packing density when compared to the aerial distribution cables of the prior art. In one example, the inventive cable had a packing density greater than 1 fiber per mm2. In general, the preferred cable designs of the invention have more than 0.5 fibers per mm. A fiber packing density is defined as the number of fibers inside per square millimeter of cable area based on the outside diameter of the cable.
    [0029] [029] Also, the inventive cable can be very light weight. For example, a 36-mm 7.0-fiber overhead cable designed according to the description above can weigh only 32.9 kg / km and a 7.0-mm 7.0-fiber overhead cable can weigh only 34.4 kg / km. km. Typically, the preferred cable designs of the invention will have a diameter of less than 10 mm and a weight of less than 40 kg / km. This light weight at a relatively small diameter ensures a relatively long span length between poles, without the use of additional fittings, and allows the installation of cables in existing aerial networks directly, without reinforcement or replacement of existing poles.
    [0030] [030] Other benefits of overhead cables designed according to the invention, besides the reduction in size, is the reduction in installation cost attributable to the installation of the cable in one step. An installation can be based on a known approved conduit, leading to minimal installation training. Also, bundling the units together with a common film makes it easier to store and manipulate the cable core in closures and installations for end users, providing installers with flexibility. Bundled units can be manipulated as a single entity or can be separated into individual subunits, at the discretion of the installer.
    [0031] [031] Considering that the emphasis in the precedent is on fiber optic cable designs adapted for aerial installations, it should be understood that these small, lightweight, high fiber count cables can find a variety of other uses. The cable structures described above can be installed in a variety of installations. Some of these are described in detail in chapter 14 of the "The Second Edition Handbook of PE Pipe", published by the Plastics Pipe Institute (http://plasticpipe.org/pdf/chapter14/pdf), incorporated here as a reference.
    [0032] [032] The following provides experimental results for the inventive aerial cable modalities.
    [0033] [033] Mechanical tests were carried out on a 7.0 mm diameter cable, a 36-fiber prototype, TR-11-092 with the structure shown in figure 2, to ensure the cable's mechanical practicality. Cyclic loading, tensile, compression, torsion, impact and temperature tests were performed following the test methods requested in the relevant TIA Fiber Optic Test Procedures (FOTPS). A bending test was performed by wrapping the cable three times around a 3 "(7.5 mm) diameter mandrel, a method commonly requested in BT plc specifications. In all cases, a fiber attenuation at 1550 nm was monitored during the application of mechanical stress, and the maximum change in attenuation was reported.The tests were performed on fibers from all three units: Unit 1: 12 OFS G.657.A1 AllWave Flex Singlemode fibers (4 tested) Unit 2: 12 OFS G.657.A1 AllWave Flex Singlemode fibers (4 tested) Unit 3: 12 OFS G.657.A1 AllWave Flex Singlemode fibers (4 tested) Test Results: 7.0 mm 36f Overhead Distribution Cable
    [0034] [034] Concluding the detailed description, it should be noted that it will be obvious to those skilled in the art that many variations and modifications can be made in the preferred embodiment, without substantially deviating from the principles of the present invention. All such variations, modifications and equivalents are intended to be included here as being within the scope of the present invention, as set out in the claims.
    权利要求:
    Claims (7)
    [0001]
    Fiber optic cable, characterized by the fact that it comprises: (a) a bundle of at least three multiple fiber tight buffer coating units, the multiple fiber tight buffer coating units each comprising: i. at least two optical fibers (21) coated in a UV-cured acrylate polymer matrix (23), the polymer matrix (23) having a first tension module, ii. a UV-cured acrylate polymer layer (23) coating the polymer matrix, the polymer layer (22) having a second stress module, where the second stress module is greater than the first stress module, (b) a thin-film containment layer (24) that surrounds the bundle of multiple fiber tight buffer coating units, and conforms to the shape of the bundle of multiple fiber tight buffer coating units, where the tension module of the polymer matrix (23) is in the range of 0.1 to 50 Mpa, and wherein the tension module of the polymer layer (22) is in the range of 100 MPa to 2000 MPa.
    [0002]
    Fiber optic cable, according to claim 1, characterized by the fact that it still includes: (c) a cable jacket (25) surrounding a thin film containment layer (24).
    [0003]
    Fiber optic cable, according to claim 1, characterized by the fact that the tension module of the polymer matrix is in the range of 0.5 to 10 MPa.
    [0004]
    Fiber optic cable according to claim 1, characterized by the fact that the tension module of the polymer layer (22) is in the range of 100 MPa to 2000 MPa.
    [0005]
    Fiber optic cable according to claim 2, characterized by the fact that the cable cross-section has a diameter of less than 10 mm.
    [0006]
    Fiber optic cable according to claim 5, characterized by the fact that the weight of the cable is less than 18.14 kg / km (40 lb / km).
    [0007]
    Fiber optic cable according to claim 2, characterized by the fact that the total number of optical fibers in the cable is greater than 12 and the fiber optic packaging density is greater than 1 fiber per square mm.
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    法律状态:
    2018-12-11| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2019-10-01| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-08-04| B09A| Decision: intention to grant|
    2020-09-24| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 27/07/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201261606033P| true| 2012-03-02|2012-03-02|
    US61/606,033|2012-03-02|
    PCT/US2012/048517|WO2013130121A1|2012-03-02|2012-07-27|Aerial optical fiber cables|
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