Distribution cable assembly having overmolded mid-span access location

• US 7,127,143 B2
• Filed: 05/24/2004
• Issued: 10/24/2006
• Est. Priority Date: 05/24/2004
• Status: Active Grant

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Cable Systems LLC (Corning Incorporated)
• Inventors: Luther, James P., Theuerkorn, Thomas, Elkins, Robert B. II, Nielsen, Lars K.
• Primary Examiner(s): PAK, SUNG H
• Application Number:
  US10/852,427
• Publication Number:
  US 20050259928A1
• Time in Patent Office: 883 Days
• Field of Search: 385100-114
• US Class Current: 385/100
• CPC Class Codes: G02B 6/4475 with provision for lateral branching G02B6/4431 takes precedence

Abstract

A fiber optic distribution cable assembly includes a distribution cable having at least one predetermined mid-span access location and a tether for mitigating cable length errors at the mid-span access location in a pre-engineered fiber optic communications network. At least one optical fiber of the distribution cable is accessed at the mid-span access location and optically connected to an optical fiber disposed within the tether. Preferably, the first end of the tether is attached to the distribution cable by overmolding the mid-span access location with a flexible encapsulant material. The end of the optical fiber of the tether may be splice-ready or connectorized at the second end of the tether and protected within a crush resistant tube. Alternatively, the second end of the tether may terminate in an optical connection terminal defining at least one optical connection node, or may terminate in a linear chain of articulated optical connection nodes.

Claims

1. A fiber optic distribution cable assembly, comprising:

a distribution cable comprising a plurality of optical fibers and having at least one predetermined mid-span access location positioned along the length of the distribution cable;

at least one optical fiber of the distribution cable accessed and terminated from the distribution cable at the mid-span access location;

a tether comprising a first end attached to the distribution cable at the mid-span access location and at least one optical fiber optically connected to the at least one terminated optical fiber of the distribution cable; and

an overmolded body formed from a flexible material encapsulating the mid-span access location, the overmolded body molded over the first end of the tether and a portion of the distribution cable adjacent the mid-span access location.

2. The fiber optic distribution cable assembly of claim 1, wherein the at least one optical fiber of the tether is optically connected to the at least one terminated optical fiber of the distribution cable within the overmolded body.

3. The fiber optic distribution cable assembly of claim 1, wherein the at least one optical fiber of the tether is optically connected to the at least one terminated optical fiber of the distribution cable outside the overmolded body.

4. The fiber optic distribution cable assembly of claim 1, wherein the tether further comprises a second end opposite the first end of the tether for presenting the at least one optical fiber of the tether for interconnection with a fiber optic branch cable or a fiber optic drop cable at a desired location that is remote from the mid-span access location.

5. The fiber optic distribution cable assembly of claim 4, wherein the end of the at least one optical fiber of the tether is splice-ready at the second end of the tether.

6. The fiber optic distribution cable assembly of claim 5, wherein the splice-ready end of the at least one optical fiber of the tether is housed within a crush resistant tube at the second end of the tether.

7. The fiber optic distribution cable assembly of claim 6, wherein the crush resistant tube and the second end of the tether are overmolded with a flexible encapsulant material.

8. The fiber optic distribution cable assembly of claim 4, wherein the end of the at least one optical fiber of the tether is connectorized at the second end of the tether.

9. The fiber optic distribution cable assembly of claim 8, wherein the connectorized end of the at least one optical fiber of the tether is housed within a crush resistant tube at the second end of the tether.

10. The fiber optic distribution cable assembly of claim 9, wherein the crush resistant tube and the second end of the tether are overmolded with a flexible encapsulant material.

11. The fiber optic distribution cable assembly of claim 4, wherein the tether further comprises an optical connection terminal at the second end of the tether defining at least one optical connection node.

12. The fiber optic distribution cable assembly of claim 11, wherein the at least one optical connection node is configured with a connector port for interconnecting at least one optical fiber of the tether having a connector mounted on the end thereof with a connectorized optical fiber of the fiber optic branch cable or the fiber optic drop cable.

13. The fiber optic distribution cable assembly of claim 11, wherein the optical connection terminal and the second end of the tether are overmolded with a flexible encapsulant material.

14. The fiber optic distribution cable assembly of claim 4, wherein the tether further comprises a plurality of optical connection nodes at the second end of the tether that are linked together to form a linear chain.

15. The fiber optic distribution cable assembly of claim 14, wherein at least one of the optical connection nodes is configured with a connector port for interconnecting at least one optical fiber of the tether having a connector mounted on the end thereof with a connectorized optical fiber of the fiber optic branch cable or the fiber optic drop cable.

16. The fiber optic distribution cable assembly of claim 14, wherein the linear chain of optical connection nodes and the second end of the tether are overmolded with a flexible encapsulant material.

17. The fiber optic distribution cable assembly of claim 14, wherein the plurality of optical connection nodes are articulated relative to one another.

18. The fiber optic distribution cable assembly of claim 1, wherein the tether has a length of up to about 100 feet.

19. The fiber optic distribution cable assembly of claim 1, wherein the tether has a length of up to about 25 feet.

20. The fiber optic distribution cable assembly of claim 1, wherein the tether has a length of between about 12 feet and about 15 feet.

21. A fiber optic distribution cable assembly, comprising:

a distribution cable comprising a plurality of optical fibers and at least one factory-prepared mid-span access location positioned along the length of the distribution cable;

at least one optical fiber of the distribution cable accessed and terminated from the distribution cable at the mid-span access location;

a tether comprising a first end attached to the distribution cable at the mid-span access location and at least one optical fiber optically connected to the at least one terminated optical fiber of the distribution cable, the tether terminating in a second end opposite the first end; and

a crush resistant tube for housing the at least one optical fiber of the tether at the second end of the tether;

wherein a section of the distribution cable and the first end of the tether are overmolded with a flexible encapsulant material and wherein the crush resistant tube and the second end of the tether are overmolded with a flexible encapsulant material.

22. The fiber optic distribution cable assembly of claim 21, wherein the at least one optical fiber of the tether at the second end is splice-ready for interconnection with an optical fiber of a fiber optic branch cable or a fiber optic drop cable.

23. A fiber optic distribution cable assembly, comprising:

a distribution cable comprising a plurality of optical fibers and at least one factory-prepared mid-span access location positioned along the length of the distribution cable;

at least one optical fiber of the distribution cable accessed and terminated from the distribution cable at the mid-span access location;

a tether comprising a first end attached to the distribution cable at the mid-span access location and at least one optical fiber optically connected to the at least one terminated optical fiber of the distribution cable, the tether terminating in a second end opposite the first end; and

an optical connection terminal defining at least one optical connection node for receiving the at least one optical fiber of the tether at the second end of the tether;

wherein a section of the distribution cable and the first end of the tether are overmolded with a flexible encapsulant material and wherein the optical connection terminal and the second end of the tether are overmolded with a flexible encapsulant material.

24. The fiber optic distribution cable assembly of claim 23, wherein the at least one optical connection node is configured with a connector port for interconnecting at least one optical fiber of the tether having a connector mounted on the end thereof with a connectorized optical fiber of a fiber optic branch cable or a fiber optic drop cable.

25. A fiber optic distribution cable assembly, comprising:

a distribution cable comprising a plurality of optical fibers and at least one factory-prepared mid-span access location positioned along the length of the distribution cable;

at least one optical fiber of the distribution cable accessed and terminated from the distribution cable at the mid-span access location;

a tether comprising a first end attached to the distribution cable at the mid-span access location and at least one optical fiber optically connected to the at least one terminated optical fiber of the distribution cable, the tether terminating in a second end opposite the first end, wherein a flexible and encapsulant material is molded around a section of the distribution cable and the first end of the tether to secure the tether to the distribution cable; and

a plurality of optical connection nodes for receiving the at least one optical fiber of the tether at the second end of the tether that are linked together to form a linear chain.

26. The fiber optic distribution cable assembly of claim 25, wherein at least one of the optical connection nodes is configured with a connector port for interconnecting at least one optical fiber of the tether having a connector mounted on the end thereof with a connectorized optical fiber of a fiber optic branch cable or a fiber optic drop cable.

27. The fiber optic distribution cable assembly of claim 25, wherein a flexible encapsulant material is molded over the linear chain of optical connection nodes and the second end of the tether.

28. The fiber optic distribution cable assembly of claim 25, wherein the plurality of optical connection nodes are articulated relative to one another.

29. The fiber optic distribution cable assembly of claim 25, wherein the tether has a length of up to about 100 feet.

30. The fiber optic distribution cable assembly of claim 25, wherein the tether has a length of up to about 25 feet.

31. The fiber optic distribution cable assembly of claim 25, wherein the tether has a length of between about 12 feet and about 15 feet.

32. A process for manufacturing a fiber optic distribution cable assembly comprising a distribution cable having a plurality of optical fibers disposed within a sheath and at least one predetermined mid-span access location and a tether having a first end attached to the distribution cable at the mid-span access location, the process comprising:

removing a section of the sheath of the distribution cable at the mid-span access location;

accessing at least one of the plurality of optical fibers of the distribution cable within the section of the sheath removed from the distribution cable;

terminating the at least one optical fiber of the distribution cable accessed from the section of the sheath removed from the distribution cable;

optically connecting the at least one terminated optical fiber of the distribution cable to an optical fiber disposed within the tether;

positioning the mid-span access location and the first end of the tether within an overmolding tool; and

molding a flexible encapsulant material around the distribution cable and the first end of the tether at the mid-span access location to securely attach the tether to the distribution cable.

33. The process for manufacturing a fiber optic distribution cable assembly of claim 32, further comprising overmolding a second end of the tether opposite the first end of the tether to protect the at least one optical fiber disposed within the tether.

34. The process for manufacturing a fiber optic distribution cable assembly of claim 32, wherein the tether has a length up to about 100 feet.

35. A method for mitigating a cable length error in a pre-engineered fiber optic communications network employing a fiber optic distribution cable assembly comprising a distribution cable having a plurality of optical fibers disposed within a sheath and at least one predetermined mid-span access location, the method comprising:

removing a section of the sheath of the distribution cable at the mid-span access location;

accessing at least one of the plurality of optical fibers of the distribution cable within the section of the sheath removed from the distribution cable;

terminating the at least one optical fiber of the distribution cable accessed within the section of the sheath removed from the distribution cable;

optically connecting the at least one terminated optical fiber of the distribution cable to an optical fiber disposed within a tether having a first end and a second end opposite the first end;

attaching the first end of the tether to the distribution cable at the mid-span access location by

deploying the distribution cable assembly in the pre-engineered fiber optic communications network; and

positioning the second end of the tether at a desired location to compensate for the cable length error.

36. The method for mitigating a cable length error in a pre-engineered fiber optic communications network of claim 35, further comprising overmolding the second end of the tether to protect the at least one optical fiber disposed within the tether.

37. The method for mitigating a cable length error in a pre-engineered fiber optic communications network of claim 35, wherein the tether has a length up to about 100 feet.