Flexible optical closure and other flexible optical assemblies

• US 7,729,583 B2
• Filed: 10/12/2007
• Issued: 06/01/2010
• 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): LEPISTO, RYAN A
• Application Number:
  US11/974,227
• Publication Number:
  US 20080063351A1
• Time in Patent Office: 963 Days
• Field of Search: 385/100, 385/102, 385/103, 385/109, 385/113, 385/134, 385/135
• US Class Current: 385/102
• CPC Class Codes: G02B 6/2558 Reinforcement of splice joint
• CPC Class Codes: G02B 6/4441 Boxes
• CPC Class Codes: G02B 6/4472 Manifolds
• CPC Class Codes: G02B 6/4475 with provision for lateral branching G02B6/4431 takes precedence

Abstract

Flexible closures and other flexible optical assemblies that are installed within a factory, or in the field, and then deployed using cable installation methods, wherein the flexible closures and assemblies have the ability to bend and twist without incurring physical damage to their structure, optical fibers and splices disposed within, and without significant attenuation in the optical fibers when exposed to conventional installation stresses. Flexible closures that replace conventional substantially rigid closures in order to facilitate pre-engineered and assembled distribution cable installation within an optical network, and the physical, bending and material properties of such closures, and methods of manufacturing and installing the same.

Claims

1. A flexible closure being attached to at least one optical fiber cable deployable using cable installation methods:

the flexible closure comprising at least one flexible protective body, the flexible protective body being formed of a resilient and flexible material thereby forming a durable and flexible body associated with and encapsulating portions of optical components associated with the flexible closure, the optical components comprising at least one optical fiber in the fiber optic cable and at least one other optical component forming an optical connection with the at least one optical fiber; and

the flexible closure being resiliently bendable and twistable in variable directions, and being flexible in response to stresses acting on the flexible closure due to cable installation equipment and maintaining mechanical integrity of the flexible closure protecting the performance on the optical components therein, wherein the flexible closure has an aspect ratio between about 10 and about 30.

2. The flexible closure of claim 1, wherein the flexible closure has a bending force ratio from about 1.0 to about 5.0.

3. The flexible closure of claim 1, wherein the resilient and flexible material used to form the flexible closure has a modulus of elasticity from about 0.001 CPa to about 3.0 CPa.

4. The flexible closure of claim 1, wherein the resilient and flexible material used to form the flexible closure has a Poisson'"'"'s ratio from about 0.30 to about 0.5.

5. The flexible closure of claim 1, wherein further optical components encapsulated by the flexible closure are selected from the group of optical connectors, splices, splitters, couplers, light sources, routers, wireless components and switches.

7. The flexible closure assembly according to claim 4, wherein the assembly is attached to a fiber optic distribution cable assembly and deployed using conventional cable installation methods, and wherein the assembly has the ability to bend without incurring physical damage to the assembly and optical fibers within, and without significant attenuation in the optical fibers when exposed to conventional installation stresses.

6. A flexible closure assembly, comprising:

at least one connector port for presenting one or more connectorized optical fibers for optical interconnection with one or more connectorized fiber optic drop cables; and

a flexible overmolded housing being formed of a resilient and flexible material thereby forming a durable and flexible body associated with and encapsulating portions of optical components associated with the flexible overmolded housing, the optical components comprising at least one optical fiber in the fiber optic cable and at least one other optical component forming an optical connection with the at least one optical fiber, wherein the flexible closure has an aspect ratio between about 10 and about 30.

8. The flexible closure assembly according to claim 6, wherein the resilient and flexible material used to form the flexible overmolded housing has a modulus of elasticity from about 0.001 CPa to about 3.0 CPa.

9. The flexible closure assembly according to claim 6, wherein the resilient and flexible material used to form the flexible overmolded housing results in a Poisson'"'"'s ratio in the assembly from about 0.30 to about 0.5.

10. The flexible closure assembly of claim 6, wherein the flexible closure has a bending force ratio from about 1.0 to about 5.0.

11. The flexible closure assembly of claim 6, wherein further optical components encapsulated by the flexible closure are selected from the group of optical connectors, splices, splitters, couplers, light sources, routers, wireless components and switches.

12. A flexible fiber optic closure, the flexible closure comprising:

(a) at least one molded portion, the at least one molded portion being formed of a resilient and flexible material covering and sealing an interconnection of optical components, the optical components comprising at least one optical fiber and at least one other optical component associated therewith; and

(b) the at least one molded portion being at least an essentially molded, monolithic form, the monolithic form being resiliently bendable and twistable in response to stresses acting on the flexible closure, wherein the flexible closure has an aspect ratio between about 10 and about 30.

13. The flexible fiber optic closure according to claim 12, wherein the optical components are selected from the group of optical fibers, optical connectors, splices, splitters, couplers, light sources, routers, wireless components and switches.

14. The flexible fiber optic closure according to claim 12, wherein the flexible closure is twistable and bendable into single arcs and combination arcs being U-shapes or S-shapes.

15. The flexible fiber optic closure according to claim 12, wherein the flexible closure has a virtual seam.

16. The flexible fiber optic closure of claim 12, wherein the flexible closure has a bending force ratio from about 1.0 to about 5.0.

17. The flexible fiber optic closure of claim 12, wherein the resilient and flexible material used to form the at least one molded portion has a modulus of elasticity from about 0.001 GPa to about 3.0 CPa.

18. The flexible fiber optic closure of claim 12, wherein the resilient and flexible material used to form the at least one molded portion has a Poisson'"'"'s ratio from about 0.30 to about 0.5.