Optical communication cable

• US 8,913,862 B1
• Filed: 04/01/2014
• Issued: 12/16/2014
• Est. Priority Date: 09/27/2013
• Status: Active Grant

• Current Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Original Assignee: Corning Optical Communications LLC (Corning Incorporated)
• Inventors: McAlpine, Warren Welborn, Wuensch, Guenter, Emmerich, Michael
• Primary Examiner(s): PENG, CHARLIE YU
• Application Number:
  US14/231,875
• Time in Patent Office: 259 Days
• Field of Search: 385/104, 385/105, 385/110, 385/111
• US Class Current: 385/103
• CPC Class Codes: G02B 6/441 built up from sub-bundles G02B6/4429, G02B6/4439, G02B6/4479 take precedence
• CPC Class Codes: G02B 6/4413 Helical structure
• CPC Class Codes: G02B 6/4429 Means specially adapted for strengthening or protecting the cables
• CPC Class Codes: G02B 6/443 Protective covering
• CPC Class Codes: G02B 6/4431 with provision in the protective covering, e.g. weak line, for gaining access to one or more fibres, e.g. for branching or tapping break-out terminations G02B6/4471
• CPC Class Codes: G02B 6/4432 with fibre reinforcements
• CPC Class Codes: G02B 6/4433 Double reinforcement laying in straight line with optical transmission element
• CPC Class Codes: G02B 6/4434 Central member to take up tensile loads

Abstract

An optical communication cable is provided. The cable includes a plurality of elongate optical transmission elements wrapped around an elongate central strength member such that a portion of the length of the plurality of wrapped elongate optical transmission elements form a spiral portion around the elongate central strength member. The cable includes an elastic sleeve surrounding the plurality of elongate optical transmission elements, and the elastic sleeve is formed from an extruded first material. The cable includes a cable body formed from an extruded second material different from the first material, and the cable body surrounds the film, and the cable body has an inner surface that faces the outer surface of the film.

Claims

1. An optical communication cable comprising:

a cable body including a passage within the cable body;

a first core element located in the passage of the cable body, the first core element including an outer surface and a first optical transmission element;

a second core element located in the passage of the cable body, the second core element including an outer surface and a second optical transmission element;

a strength member located in the passage of the cable body, wherein the first core element and the second core element are wound around the strength member; and

a film formed from a first polyethylene material located within the passage of the cable body, the film surrounding the first core element, the second core element and the strength member, wherein the film applies a radial inwardly directed force to the outer surface of the first core element and the outer surface of the second core element;

wherein the cable body is formed from a second polyethylene material different from the first polyethylene material, the cable body surrounding the film, the cable body having an inner surface that faces the outer surface of the film, wherein the outer surface of the film and the inner surface of the cable body contact one another at an interface therebetween where the first and second polyethylene materials are bonded to one another, facilitating simultaneous opening or removal of the cable body and film together.

2. The optical communication cable of claim 1 wherein the radially inwardly directed force is evenly distributed around the first core element and the second core element at a first axial position along the cable body.

3. The optical communication cable of claim 1

wherein the first core element includes a first tube having an inner surface defining a bore, wherein the first optical transmission element is located within the bore of the first tube, wherein the second core element includes a second tube having an inner surface defining a bore, wherein the second optical transmission element is located within the bore of the second tube,

wherein the diameter of the bore of the first tube is between 0.5 mm and 3.0 mm, wherein the diameter of the bore of the second tube is between 0.5 mm and 3.0 mm,

wherein the inner surface of the first tube is in contact with a portion of an outer surface of the first optical transmission element, wherein the inner surface of the second tube is in contact with a portion of an outer surface of the second optical transmission element.

4. The optical communication cable of claim 3

wherein the first optical transmission element includes at least nine optical fibers and the second optical transmission element includes at least nine optical fibers,

wherein an inner surface of the film contacts the outer surface of the first core element and the outer surface of the second core element.

5. The optical communication cable of claim 4

wherein the film has a thickness that is less 100 micrometers, and the cable body has a thickness greater than 1 millimeter,

wherein an outer diameter of the cable body is between 4 millimeters and 10 millimeters.

6. The optical communication cable of claim 1 wherein the first core element and the second core element are wrapped around the strength member such that the wrapped first and second core elements include a plurality of left-handed spirally wrapped sections, a plurality of right-handed spirally wrapped sections and a plurality of reversal sections providing transitions between the left-handed spirally wrapped sections and the right-handed spirally wrapped sections.

7. The optical communication cable of claim 6

wherein each left-handed spirally wrapped section includes less than 10 revolutions and more than one half revolution between reversals and each right-handed spirally wrapped section includes less than 10 revolutions and more than one half revolution between reversals,

wherein the cable does not include a helically wrapped binder element located between the first and second core elements and the cable body.

8. The optical communication cable of claim 7 wherein the inner surface of the film is in substantially continuous contact with the outer surface of the first core element and the outer surface of the second core element extending axially over at least one left-handed spirally wrapped section, at least one right-handed spirally wrapped section, and at least one reversal.

16. The optical communication cable of claim 1, wherein the first polyethylene material of the film is a lower density polyethylene material than the second polyethylene material of the body.

17. The optical communication cable of claim 16, wherein the second polyethylene material of the body has a high density, in the range of 0.93 to 0.97 g/cm³.

18. The optical communication cable of claim 1, wherein the body comprises a discontinuity that extends axially through the body, whereby the discontinuity facilitates opening of body by tearing, and wherein the film is bonded to body such that the film buttresses the body, thereby limiting chances of accidental opening or splitting along the discontinuity.

19. The optical communication cable of claim 1, wherein the cable body is thicker than the film.

9. An optical communication cable comprising:

a cable body including a bore within the cable body;

an elongate central strength member located in a central area of the bore;

a plurality of elongate optical transmission elements wrapped around the elongate central strength member such that a portion of a length of the plurality of wrapped elongate optical transmission elements forms a spiral portion around the elongate central strength member; and

an extruded membrane surrounding the plurality of elongate optical transmission elements, the extruded membrane formed from a first material,

wherein the extruded membrane is contiguous in a circumferential direction around the elongate optical transmission elements and is contiguous in an axial direction for at least one revolution of the elongate optical transmission elements around the elongate central strength member within the spiral portion,

wherein the membrane contacts an outer surface of each of the plurality of elongate optical transmission elements within the spiral portion;

wherein the membrane forms an undulating pattern in cross-section, which includes interspaced convex portions and concave portions as the extruded membrane contacts and extends between each of the plurality of elongate optical transmission elements within the spiral portion, and wherein the membrane applies a radial inwardly directed force to the outer surface of the plurality of elongate optical transmission elements, limiting the elongate optical transmission elements from unwinding from around the elongate central strength member;

wherein the cable body is formed from an extruded second material, the cable body surrounding the membrane, the cable body having an inner surface that faces the outer surface of the membrane.

10. The optical communication cable of claim 9 wherein the extruded membrane has a thickness less than 100 micrometers.

11. The optical communication cable of claim 9 wherein at least one of the optical transmission elements is a tight buffered optical fiber.

12. The optical communication cable of claim 9 wherein the spiral portion includes at least five adjacent revolutions in the right-hand direction, wherein the membrane applies a radial inwardly directed force to the outer surface of each of the plurality of elongate optical transmission elements extending over at least five adjacent revolutions of the spiral portion.

13. The optical communication cable of claim 9 wherein the plurality of optical transmission elements are wrapped around the elongate central strength member such that the plurality of optical transmission elements include a plurality of left-handed spirally wrapped sections, a plurality of right-handed spirally wrapped sections and a plurality of reversal sections providing transitions between the left-handed spirally wrapped sections and the right-handed spirally wrapped sections.

14. The optical communication cable of claim 13 wherein each left-handed spirally wrapped section includes less than 10 revolutions and more than one half revolution between reversals and each right-handed spirally wrapped section includes less than 10 revolutions and more than one half revolution.

15. The optical communication cable of claim 14 wherein an inner surface of the membrane is in substantially continuous contact with the outer surface of each of the plurality of elongate optical transmission elements extending over one of the left-handed spirally wrapped sections, one of the right-handed spirally wrapped sections and the reversal section located between the left-handed spirally wrapped section and the right-handed spirally wrapped section.

20. The optical communication cable of claim 9, wherein the body comprises a discontinuity that extends axially through the body, whereby the discontinuity facilitates opening of body by tearing, and wherein the membrane is bonded to body such that the membrane buttresses the body, thereby limiting chances of accidental opening or splitting along the discontinuity.

21. The optical communication cable of claim 9, wherein the cable body is thicker than the membrane.

22. An optical communication cable, comprising:

a cable jacket having an inner surface that defines a cavity, wherein the optical communication cable has an outer diameter of no greater than 12 millimeters;

a central strength member located in a central area of the cavity;

buffer tubes wrapped around the central strength member in an SZ stranding pattern, wherein the buffer tubes each have an inner diameter of between 0.5 and 3.0 millimeters, wherein the buffer tubes carry optical fibers, wherein the optical fibers in the buffer tubes have EFL of about 0.1% or less per optical fiber on average; and

a thin film binder surrounding the buffer tubes, the thin film binder formed from a first polymer,

wherein the thin film binder is contiguous in a circumferential direction around the buffer tubes and is contiguous in an axial direction for at least one revolution of the buffer tubes around the central strength member within the SZ stranding pattern,

wherein the thin film binder forms an undulating pattern in cross-section, which includes interspaced convex portions and concave portions as the thin film binder contacts and extends between individual ones of the buffer tubes, and wherein the thin film binder applies a radial inwardly directed force to the outer surface of the buffer tubes, limiting the buffer tubes from unwinding from around the central strength member;

wherein the cable jacket is formed from a second polymer, the cable jacket surrounding the thin film binder, the cable jacket having an inner surface that faces the outer surface of the thin film binder.

23. The optical communication cable of claim 22, wherein the optical communication cable has an outer diameter of at least 4 millimeters.

24. The optical communication cable of claim 22, wherein the optical communication cable is a minicable with the central strength member having a diameter of no more than about 5 millimeters.

25. The optical communication cable of claim 22, wherein at least some of the optical fibers have diameters of 210 micrometers or less.

26. The optical communication cable of claim 22, wherein the cable jacket is thicker than the thin film binder, and wherein the wall thickness of the jacket is at least 0.3 millimeters.

27. An optical communication cable comprising:

a cable jacket having an inner surface that defines a cavity, wherein the optical communication cable has an outer diameter of no greater than 12 millimeters;

a first buffer tube located in the cavity of the cable jacket, the first buffer tube including an outer surface, wherein the first buffer tube has an inner diameter of between 0.5 and 3.0 millimeters, wherein the first buffer tube carries optical fibers, wherein the optical fibers in the first buffer tube have EFL of about 0.1% or less per optical fiber on average;

a second buffer tube located in the cavity of the cable jacket, the second buffer tube including an outer surface, wherein the second buffer tube has an inner diameter of between 0.5 and 3.0 millimeters, wherein the second buffer tube carries optical fibers, wherein the optical fibers in the second buffer tube have EFL of about 0.1% or less per optical fiber on average;

a central strength member located in the cavity of the cable jacket, wherein the first and second buffer tubes are wound around the central strength member, wherein the first and second buffer tubes are wrapped around the central strength member in an SZ stranding pattern; and

a thin film binder formed from a first polyethylene material located within the cavity of the cable jacket, the thin film binder surrounding the first buffer tube, the second buffer tube and the central strength member, wherein the thin film binder applies a radial inwardly directed force to the outer surfaces of the first and second buffer tubes;

wherein the cable body is thicker than the film;

wherein the cable jacket is formed from a second polyethylene material different from the first polyethylene material, the cable jacket surrounding the thin film binder, the cable jacket having an inner surface that faces an outer surface of the thin film binder, wherein the outer surface of the thin film binder and the inner surface of the cable jacket contact one another at an interface therebetween where the first and second polyethylene materials are bonded to one another, facilitating simultaneous opening or removal of the cable jacket and thin film binder together.

28. The optical communication cable of claim 27, wherein the first polyethylene material of the film is a lower density polyethylene material than the second polyethylene material of the body.

29. The optical communication cable of claim 28, wherein the second polyethylene material of the body has a high density, in the range of 0.93 to 0.97 g/cm³.

30. The optical communication cable of claim 27, wherein the body comprises a discontinuity that extends axially through the body, whereby the discontinuity facilitates opening of body by tearing, and wherein the film is bonded to body such that the film buttresses the body, thereby limiting chances of accidental opening or splitting along the discontinuity.