US20100080514A1 - Fiber optic cable breakout configuration with retention block - Google Patents
Fiber optic cable breakout configuration with retention block Download PDFInfo
- Publication number
- US20100080514A1 US20100080514A1 US12/612,182 US61218209A US2010080514A1 US 20100080514 A1 US20100080514 A1 US 20100080514A1 US 61218209 A US61218209 A US 61218209A US 2010080514 A1 US2010080514 A1 US 2010080514A1
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- United States
- Prior art keywords
- tether
- cable
- base
- retention block
- buffer tube
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- Abandoned
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Classifications
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4439—Auxiliary devices
- G02B6/4471—Terminating devices ; Cable clamps
- G02B6/4472—Manifolds
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4439—Auxiliary devices
- G02B6/4471—Terminating devices ; Cable clamps
- G02B6/4472—Manifolds
- G02B6/4475—Manifolds with provision for lateral branching
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4439—Auxiliary devices
- G02B6/4471—Terminating devices ; Cable clamps
- G02B6/4476—Terminating devices ; Cable clamps with heat-shrinkable elements
Definitions
- the principles disclosed herein relate to fiber optic cable systems. More particularly, the present disclosure relates to fiber optic cable systems having main cables and branch cables.
- Passive optical networks are becoming prevalent in part because service providers want to deliver high bandwidth communication capabilities to customers. Passive optical networks are a desirable choice for delivering high-speed communication data because they may not employ active electronic devices, such as amplifiers and repeaters, between a central office and a subscriber termination. The absence of active electronic devices may decrease network complexity and/or cost and may increase network reliability.
- FIG. 1 illustrates a network 100 deploying passive fiber optic lines.
- the network 100 may include a central office 110 that connects a number of end subscribers 115 (also called end users 115 herein) in a network.
- the central office 110 may additionally connect to a larger network such as the Internet (not shown) and a public switched telephone network (PSTN).
- PSTN public switched telephone network
- the network 100 may also include fiber distribution hubs (FDHs) 130 having one or more optical splitters (e.g., 1-to-8 splitters, 1-to-16 splitters, or 1-to-32 splitters) that generate a number of individual fibers that may lead to the premises of an end user 115 .
- the various lines of the network can be aerial or housed within underground conduits (e.g., see conduit 105 ).
- the portion of network 100 that is closest to central office 110 is generally referred to as the F 1 region, where F 1 is the “feeder fiber” from the central office.
- the F 1 portion of the network may include a distribution cable having on the order of 12 to 48 fibers; however, alternative implementations may include fewer or more fibers.
- the portion of network 100 that includes an FDH 130 and a number of end users 115 may be referred to as an F 2 portion of network 100 .
- Splitters used in an FDH 130 may accept a feeder cable having a number of fibers and may split those incoming fibers into, for example, 216 to 432 individual distribution fibers that may be associated with a like number of end user locations.
- the network 100 includes a plurality of breakout locations 125 at which branch cables (e.g., drop cables, stub cables, etc.) are separated out from main cables (e.g., distribution cables).
- Breakout locations can also be referred to as tap locations or branch locations and branch cables can also be referred to as breakout cables.
- fibers of the branch cables are typically spliced to selected fibers of the main cable.
- the interface between the fibers of the main cable and the fibers of the branch cables can be connectorized.
- Stub cables are typically branch cables that are routed from breakout locations to intermediate access locations such as a pedestals, drop terminals or hubs. Intermediate access locations can provide connector interfaces located between breakout locations and subscriber locations.
- a drop cable is a cable that typically forms the last leg to a subscriber location. For example, drop cables are routed from intermediate access locations to subscriber locations. Drop cables can also be routed directly from breakout locations to subscriber locations hereby bypassing any intermediate access locations
- Branch cables can manually be separated out from a main cable in the field using field splices.
- Field splices are typically housed within sealed splice enclosures. Manual splicing in the field is time consuming and expensive.
- Pre-terminated cable systems include factory integrated breakout locations manufactured at predetermined positions along the length of a main cable (e.g., see U.S. Pat. Nos. 4,961,623; 5,125,060; and 5,210,812).
- pre-terminated cables can be difficult.
- pre-terminations can complicate passing pre-terminated cable through the underground conduit typically used to hold fiber optic cable (e.g., 1.25 inch inner diameter conduit).
- fiber optic cable e.g., 1.25 inch inner diameter conduit
- aerial applications pre-terminations can complicate passing pre-terminated cable through aerial cable retention loops.
- Certain aspects of the disclosure relate to mid-span breakout configurations for pre-terminated fiber optic distribution cables.
- inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
- FIG. 1 shows a prior art passive fiber optic network
- FIG. 2 is a cross sectional view of an example distribution cable
- FIG. 3 is a side view of a mid-span breakout location having features that are examples of inventive aspects in accordance with the principles of the present disclosure
- FIG. 4 is a left end view of the mid-span breakout location of FIG. 3 ;
- FIG. 5 is a right end view of the mid-span breakout location of FIG. 3 ;
- FIG. 6 is a side view of the mid-span breakout location of FIG. 3 with the overmold removed;
- FIG. 7 is a side view of the mid-span breakout location of FIG. 3 with the overmold and protective sleeve removed;
- FIG. 7A is a cross sectional view taken along section line 7 A- 7 A of FIG. 7 ;
- FIG. 7B is a cross sectional view taken along section line 7 B- 7 B of FIG. 7 ;
- FIG. 8 is a cross sectional view of the tether taken along section line 8 - 8 of FIG. 7 ;
- FIG. 9 is a perspective view of a base of a retention block used at the mid-span breakout location of FIG. 3 ;
- FIG. 10 is a front side view of the base of FIG. 9 ;
- FIG. 11 is a top view of the base of FIG. 9 ;
- FIG. 12 is a bottom view of the base of FIG. 9 ;
- FIG. 13 is a left end view of the base of FIG. 9 ;
- FIG. 14 is a right end view of the base of FIG. 9 ;
- FIG. 15 is a perspective view of a cover adapted to mount to the base of FIG. 9 ;
- FIG. 16 is a top view of the cover of FIG. 15 ;
- FIG. 17 is a front side view of the cover of FIG. 15 ;
- FIG. 18 is an underside view of the cover of FIG. 15 ;
- FIG. 19 is a right end view of the cover of FIG. 15 ;
- FIG. 20 is a perspective view of a splice stiffener used at the mid-span breakout location of FIG. 3 ;
- FIG. 21 is a front side view of the splice stiffener of FIG. 20 ;
- FIG. 22 is a top view of the splice stiffener of FIG. 20 ;
- FIG. 23 is a bottom view of the splice stiffener of FIG. 20 ;
- FIG. 24 is a right end view of the splice stiffener of FIG. 20 ;
- FIG. 25 is a cross sectional view taken along section line 25 - 25 of FIG. 22 ;
- FIG. 26 is a cross sectional view taken along section line 26 - 26 of FIG. 21 , the splice stiffener is shown mounted on a distribution cable;
- FIG. 27 is a perspective view of a stiffener used at the mid-span breakout location of FIG. 3 ;
- FIG. 28 is a front side view of the stiffener of FIG. 27 ;
- FIG. 29 is a cross sectional view taken along section line 29 - 29 of FIG. 28 ;
- FIG. 30 is a cross sectional view taken along section line 30 - 30 of FIG. 28 ;
- FIG. 31 is a perspective view of a protective sleeve used at the mid-span breakout location of FIG. 3 ;
- FIG. 32 is a front side view of the protective sleeve of FIG. 31 ;
- FIG. 33 is a right end view of the protective sleeve of FIG. 31 ;
- FIG. 34 is a left end view of the protective sleeve of FIG. 31 ;
- FIG. 35 is a top view of the protective sleeve of FIG. 31 ;
- FIG. 36 is a cross sectional view taken along section line 36 - 36 of FIG. 32 ;
- FIG. 37 is a cross sectional view taken along section line 37 - 37 of FIG. 32 ;
- FIG. 38 is a perspective view of a retention clip used to retain the protective sleeve of FIG. 31 at the mid-span breakout location of FIG. 3 ;
- FIG. 39 is a front side view of the retention clip of FIG. 38 ;
- FIG. 40 is a top view of the retention clip of FIG. 38 ;
- FIG. 41 is a bottom view of the retention clip of FIG. 38 ;
- FIG. 42 is a right end view of the retention clip of FIG. 38 ;
- FIG. 43 is a side view of an overmold used at the mid-span breakout location of FIG. 3 ;
- FIG. 44 is a top view of the overmold of FIG. 43 ;
- FIG. 45 is a bottom view of the overmold of FIG. 43 ;
- FIG. 46 is a left end view of the overmold of FIG. 43 ;
- FIGS. 47 and 48 are schematic views showing a method for providing excess fiber length at the mid-span breakout location of FIG. 3 ;
- FIG. 49 is a schematic view showing a distribution cable bent along a 90 degree curve at a maximum bend radius
- FIG. 50 shows a first preparation step for a tether used at the mid-span breakout location of FIG. 3 ;
- FIG. 51 shows a subsequent preparation step of the tether of FIG. 50 ;
- FIG. 52 shows an initial preparation of the distribution cable at the mid-span breakout location
- FIG. 53 is a perspective view of an example mid-span breakout assembly
- FIG. 54 is a perspective view of an example retention block
- FIG. 55 is a perspective view of a base of the retention block of FIG. 54 ;
- FIG. 56 is a top view of the base of FIG. 55 ;
- FIG. 57 is a bottom perspective view of the base of FIG. 55 ;
- FIG. 58 is a side view of the base of FIG. 55 ;
- FIG. 59 is a transverse cross-sectional view of the base of FIG. 55 ;
- FIG. 60 is a front view of the base of FIG. 55 ;
- FIG. 61 is a top perspective view of a cover of the retention block of FIG. 54 ;
- FIG. 62 is a bottom perspective view of the cover of FIG. 61 ;
- FIG. 63 is a side view of the cover of FIG. 61 ;
- FIG. 64 is a top view of the cover of FIG. 61 ;
- FIG. 65 is a transverse cross-sectional view of the cover of FIG. 61 ;
- FIG. 66 is a front view of the cover of FIG. 61 ;
- FIG. 67 is a top view of the cover of FIG. 61 showing preparation of a tether cable at an example mid-span breakout location;
- FIG. 68 is a front perspective view of an example separation block
- FIG. 69 is a front perspective view of an example first section of the separation block of FIG. 68 ;
- FIG. 70 is a rear perspective view of the first section of FIG. 69 ;
- FIG. 71 is a side view of the first section of FIG. 69 ;
- FIG. 72 is a top view of the first section of FIG. 69 ;
- FIG. 73 is a rear view of the first section of FIG. 69 ;
- FIG. 74 is a rear perspective view of an example second section of the separation block of FIG. 68 ;
- FIG. 75 is a front perspective view of the second section of FIG. 74 ;
- FIG. 76 is a side view of the second section of FIG. 74 ;
- FIG. 77 is a top view of the second section of FIG. 74 ;
- FIG. 78 is a cross-sectional view of the first section of FIG. 74 ;
- FIG. 79 is a side view of the second section of FIG. 74 showing preparation of a distribution cable at an example mid-span breakout location.
- a typical distribution cable includes a relatively large number of fibers (e.g., 72, 144 or more fibers).
- the fibers are typically segregated into separate groups with each group contained within a separate buffer tube.
- the fibers within each buffer tube can include either ribbon fibers or loose fibers.
- FIG. 2 shows an example distribution cable 220 including six separate buffer tubes 222 each containing twelve fibers 224 .
- the buffer tubes 222 may be gel filled.
- the distribution cable 220 also includes a central strength member 226 for reinforcing the cable 220 , and an outer strength member 228 such as Kevlar for also reinforcing the cable.
- the distribution cable 220 further includes an outer jacket 230 that encloses the buffer tubes 222 . Ripcords 232 can be provided for facilitating tearing away portions of the jacket 230 to access the fibers 224 within the jacket 230 .
- the various aspects of the present disclosure are also applicable to distribution cables having fewer numbers of fibers (e.g., 2 or more fibers).
- the distribution cable can include an outer jacket enclosing a single buffer tube and at least two strength members extending on opposite sides of the single buffer tube.
- An outer strength member such as Kevlar can surround the single buffer tube within the jacket.
- the single buffer tube can enclose loose fibers or ribbon fibers.
- a typical mid-span breakout location is provided at an intermediate point along the length of a distribution cable.
- a tether e.g., a drop cable or a stub cable
- branches out from the distribution cable at the breakout location e.g., a drop cable or a stub cable.
- the tether most commonly has a fewer number of fibers as compared to the number of fibers provided within the distribution cable. In an example embodiment, the tether has no more than twelve fibers.
- the tether includes fibers that extend between first and second ends. The first ends of the tether fibers are preferably spliced to selected fibers of the distribution cable at the breakout location. The second ends of the tether fibers can either be connectorized or unconnectorized.
- FIGS. 3-7 illustrate a mid-span breakout assembly 240 having features that are examples of inventive aspects in accordance with the principles of the present disclosure.
- the breakout assembly is positioned at a mid-span breakout location 241 .
- a tether 242 branches outwardly from a main distribution cable 220 at the mid-span breakout location 241 .
- the breakout location 241 is shown including a splice location 244 where selected fibers 224 dc of the main distribution cable 220 (e.g., typically less than twelve fibers) are spliced to corresponding fibers 224 t of the tether 242 .
- the breakout assembly includes a splice sleeve 246 positioned over the splices, and a splice stiffener 248 for holding the splice sleeve 246 .
- the breakout assembly 240 also includes stiffeners 250 1 , 250 2 between which the splice stiffener 248 is positioned.
- the fibers 224 dc from the distribution cable 220 pass through the stiffener 250 1 to reach the splice location 244 .
- the fibers 224 t from the tether 242 pass through the stiffener 250 2 to reach the splice location 244 .
- the breakout assembly 240 further includes a protective sleeve 252 (e.g., a shell) that covers the breakout location 241 .
- the stiffeners 250 1 , 250 2 and the splice stiffener 248 are all enclosed within the sleeve 252 .
- a first end 254 of the sleeve 252 forms a tapered nose, and a second end 256 of the sleeve 252 overlaps a retention block 258 through which the fibers 224 t of the tether 242 pass.
- Retention clips 243 are used to secure the protective sleeve 252 to the distribution cable 220 .
- the breakout assembly 240 also includes an over-mold (i.e., a flexible closure) 260 that encloses and seals the protective sleeve 252 , the clips 243 and the retention block 258 .
- a wrap of heat resistant tape 263 can provide an intermediate layer between the protective sleeve 252 and the over-mold 260 .
- the tether 242 joined to the distribution cable 220 at the breakout location 241 is depicted as having a flat cable configuration.
- the flat cable configuration includes a central buffer tube 262 containing a plurality of fibers 224 t (e.g., typically one to twelve loose or ribbonized fibers).
- Strength members 264 e.g., flexible rods formed by glass fiber reinforced epoxy
- An outer jacket 266 surrounds the strength members 264 and the buffer tube 262 .
- the outer jacket 266 includes an outer perimeter having an elongated transverse cross-sectional shape.
- An additional strength layer 265 (e.g., Kevlar) can be positioned between the buffer tube 262 and the outer jacket 266 .
- the transverse cross-sectional shape includes oppositely positioned, generally parallel sides 268 interconnected by rounded ends 270 .
- the retention block 258 is used to strengthen the mechanical interface between the tether 242 and the distribution cable 220 .
- the retention block 258 includes a base 280 (i.e., or first portion) and a cover 282 (i.e., or second portion) between which the tether 242 extends.
- the retention block 258 has a plastic construction.
- the base 280 of the retention block 258 includes a first end 284 positioned opposite from a second end 286 .
- the base 280 is elongated along a length A that extends between the first and second ends 284 , 286 .
- the base also includes a first side 288 adapted to engage the outer surface of the distribution cable jacket, and a second side 290 adapted to engage the tether 242 .
- the first side 288 has a channel 292 that extends along the length L of the base 280 .
- the channel 292 has a transverse cross-sectional shape that is curved to match the outer diameter of the distribution cable jacket 230 .
- the second side 290 of the base 280 includes a retention sleeve 294 defining an elongate opening 296 having a transverse cross-sectional shape that matches the transverse cross-sectional shape of the outer perimeter of the tether cable jacket 266 .
- a jacketed portion of the tether 242 fits within the sleeve 294 (see FIG. 7A ).
- the second side 290 of the base 280 also includes a central groove 298 a and two side grooves 300 a .
- the grooves 298 a , 300 a are generally parallel and extend along the length of the retention block 258 .
- the central groove 298 a is sized to receive the buffer tube 262 of the tether 242 .
- the side grooves 300 a are sized to receive the strength members 264 of the tether 242 .
- the base 280 also includes structures for resisting axial movement between the retention block 258 and the over-mold 260 .
- surface depressions 302 are provided adjacent the second end 286 of the base 280 .
- the surface depressions 302 (e.g., grooves, slots, cuts, notches, indentations) provide void regions for allowing over-mold material to fill-in during the over-molding process to provide a more secure connection between the retention block 258 and the outer over-mold 260 .
- a mechanical interlock is formed that resists axial movement between the retention block 258 and the over-mold 260 .
- the base 280 can include outwardly projecting structures (e.g., flanges, bumps, ribs) that are embedded in the over-mold to further resist axial movement between the over-mold and the retention block.
- the cover 282 of the retention block 258 mounts over the second side 290 of the base 280 adjacent the first end 284 of the base 280 .
- the cover 282 includes a central groove 298 b and two side grooves 300 b .
- the central groove 298 b aligns with the central groove 298 a of the base 280
- the side grooves 300 b align with the side grooves 300 a of the base 280 .
- the buffer tube 262 of the tether 242 is captured within the central grooves 298 a , 298 b , and the strength members 264 of the tether 242 are captured within the side grooves 300 a , 300 b (see FIG. 7B ).
- An adhesive 299 can be applied between the cover 282 and the base 280 to securely affix the tether 242 to the retention block 258 .
- the adhesive 299 is applied to the second side 290 of the base 280 , the grooved side of the cover 282 , the buffer tube 262 of the tether 242 , and the strength members 264 of the tether 242 .
- the retention block 258 also includes structures for facilitating aligning the cover 282 on the base 280 .
- the retention block 258 can include mating posts 304 and holes 306 provided on the cover 282 and the base 280 .
- the posts 304 fit within the holes 306 to maintain alignment between the base 280 and the cover 282 during assembly.
- the retention block 258 further includes an outer band groove 308 (see FIGS. 9 and 15 ) that extends around at least a portion of the perimeter of the retention block 258 .
- the band groove 308 is sized to receive a strap or band 297 (see FIG. 7 ) that is wrapped around the retention block 258 and the distribution cable 220 to secure the retention block 258 to the distribution cable 258 .
- the band can also function to assist in holding the cover 282 on the base 280 .
- the splice stiffener 248 of the breakout assembly 240 preferably has a crush-resistant construction adapted to prevent the splices of the breakout location 241 from being damaged.
- the splice stiffener 248 is made of a plastic material.
- the splice stiffener 248 includes an elongated base portion 320 having a generally half-cylinder shape.
- the base portion 320 includes first and second sides 322 , 324 that face in opposite directions.
- the first side 322 of the base portion 320 includes a concave surface 325 defining a channel 326 having an open side.
- the concave surface 325 is adapted to face toward the buffer tubes 222 of the distribution cable 220 .
- the concave surface 325 has a semi-circular shape having a curvature that generally matches an outer diameter D circumscribing the buffer tubes 322 of the distribution cable 320 .
- the concave surface 325 is shown covering approximately one half the diameter D, and a plurality of the buffer tubes 222 are shown positioned within the channel 326 .
- the layer formed by the strength members 228 may be positioned between the surface 325 and the buffer tubes 222 .
- the splice stiffener 248 also includes a pair of parallel retaining members 328 that project outwardly from the second side 324 of the base portion 320 .
- a splice retention channel 330 having an open side is defined between the retaining members 328 .
- a bed 332 of the channel 330 is generally planar.
- Splice sleeve retention ridges or shoulders 334 project outwardly from the bed 332 adjacent opposite ends of the channel 330 .
- Snap fit tabs 336 project laterally into the channel 330 from the retaining members 328 . In use, the splice sleeve 246 is snap fit between the tabs 336 and into the channel 330 .
- the tabs 336 prevent the splice sleeve 246 from unintentionally exiting the splice retention channel 330 through the open side.
- the retention shoulders 334 prevent the splice sleeve 246 from sliding out of the splice retention channel 330 through the ends of the splice retention channel 330 .
- the splice sleeve 246 is free to slide back and forth between the shoulders 334 within the channel 330 .
- the stiffeners 250 1 , 250 2 of the breakout assembly 240 are preferably configured to provide increased crush resistance to the protective sleeve 252 .
- the stiffeners 250 1 , 250 2 have a stiffer construction than the protective sleeve 252 and are made of a plastic material.
- the stiffeners 250 1 , 250 2 have a generally tubular configuration and each define a through-passage 340 for receiving their respective fibers 224 dc and 224 t .
- the through-passages 340 preferably have large enough cross-sectional areas to allow the fibers 224 dc , 224 t to freely slide therein when the breakout location 241 is bent.
- Ends 342 of the passages 340 preferably include contours that extend around the perimeter of the passages 340 for preventing the fibers from being bent beyond acceptable bend radius requirements.
- the stiffeners 250 1 , 250 2 each include a base portion 344 spaced from an arcuate dome portion 346 .
- the stiffeners 250 1 , 250 2 each also include a pair of planar, generally parallel side walls 348 that connect the base portion 344 to the dome portion 346 .
- the base portions 344 define concave channels 350 adapted to receive buffer tubes 222 of the distribution cable 220 when the stiffeners 250 1 , 250 2 are positioned at the breakout location 241 .
- the sidewalls 348 and the dome portion 346 define an exterior shape that generally matches the interior shape of the protective sleeve 252 .
- the protective sleeve 252 of the mid-span breakout assembly 240 is adapted to form a protective shell over the breakout location 241 .
- the protective sleeve 252 is preferably sufficiently flexible to allow the pre-terminated cable (i.e., the distribution cable 220 with the tethers terminated 242 thereto) to be readily stored on a spool.
- the stiffeners 248 , 250 1 , 250 2 provide regions/segments of increased crush resistance separated by regions/segments of increased flexibility.
- the protective sleeve 252 is elongated along a length that extends between the first end 254 and the second end 256 and has a generally U-shaped transverse cross section forming a channel 360 (see FIG. 36 ) with an open side sized to be inserted over the distribution cable.
- the channel 360 has a cross sectional shape sized to conform generally with the outer cross sectional shape of the stiffeners 250 1 , 250 2 .
- the internal transverse cross sectional shape of the channel 360 is sized to accommodate sufficient slack or excess fiber length to allow the breakout location 241 to be bent without negatively affecting performance or damaging the fibers of the breakout location.
- the channel 360 of the protective sleeve 252 is defined between opposing sidewalls 362 defining openings 364 for receiving snap-fit tabs 366 of the retention clips 243 .
- the sidewalls 362 are interconnected by a curved portion 363 .
- the first end 254 of the protective sleeve 252 includes a low profile portion 365 that fits closely to the distribution cable 220 .
- the low profile portion 365 includes a channel 367 that receives the outer jacket 230 of the distribution cable 220 .
- the channel 367 has a diameter that generally matches the outer diameter of the distribution cable 220 .
- the first end 254 also includes a transition portion 369 that provides a smooth taper/contour between the low profile portion 365 and a main body of the protective sleeve 252 .
- the low profile portion 365 and the transition portion 369 cooperate to provide a smooth transition from the distribution cable 220 to the main outer surface of the protective sleeve 252 .
- the smooth taper provided by the first end (i.e., the leading end/nose) of the protective sleeve 252 assists in pulling the cable through underground conduit without snagging the breakout location 241 .
- the second end 256 of the protective sleeve 252 forms an enlarged receptacle 372 sized sufficiently large to receive the retention block 258 .
- a tapered transition portion 370 is provided between the main body of the protective sleeve 252 and the enlarged receptacle 372 .
- the retention clips 243 of the mid-span breakout assembly 240 include curved portions 380 that receive the distribution cable 220 on the opposite side of the protective sleeve 252 such that the distribution cable 220 is captured between the clips 243 and the protective sleeve 252 .
- the clips 243 also include straight extensions 382 that project upwardly from the curved portion 380 .
- the extensions 382 of the clips 243 fit inside the protective sleeve 252 and assist in preventing fibers 224 dc , 224 t from being pinched between the protective sleeve 252 and the distribution cable 220 or the clips 243 .
- the extensions 382 include snap-fit tabs 366 that fit within the openings 364 of the protective sleeve 252 .
- the clips 243 also include discrete stops 384 for engaging bottom edges of the protection sleeve 252 .
- the stops 384 are located at the exteriors of the clips 343 and project outwardly from the curved portions 380 .
- the over-mold 260 of the mid-span breakout assembly 240 is preferably made of a polymer plastic material. As shown at FIGS. 43-46 , the over-mold 260 has a primary contour 390 at a leading edge configured to coincide generally with the contour of the leading end of the protective sleeve 252 . A trailing end 392 of the over-mold 260 is also slightly contoured.
- the transverse cross sectional shape of the over-mold includes first and second curved portions 395 , 396 interconnected by generally planar portions 397 , 398 .
- the over-mold 360 is sized with a cross sectional shape sufficient to allow the breakout location to be readily passed through a one and one-half inch inner diameter conduit or a one and one-quarter inch diameter conduit.
- the breakout location has a cross sectional area that can be passed through a one inch inner diameter conduit.
- the mid-span breakout location 241 is preferably configured to allow the mid-span breakout location to be bent/flexed in any orientation without damaging the fibers 224 dc , 224 t and without significantly negatively affecting cable performance. In one embodiment, this flexibility is provided by making sure that the fibers 224 dc , 224 t have sufficient excess fiber length (i.e., slack) to allow the breakout location to be bent/flexed the requisite amount. In one embodiment, the fibers 224 dc , 224 t that extend along the mid-span breakout location 241 are provided with at least 2% excess fiber length. In other embodiments, the fibers 224 dc , 224 t are provided with at least 3% excess fiber length.
- the fibers 224 dc , 224 t are provided with an excess fiber length in the range of 1 to 5% or in the range of 2 to 5%.
- the length of the mid-span breakout location 241 is about 32 centimeters and about 1 centimeter of excess fiber length is provided to the fibers 224 dc , 224 t as they extend along the mid-span breakout location 241 .
- the mid-span breakout assembly 240 When the mid-span breakout assembly 240 is assembled, measures are taken to provide the fibers 224 dc , 224 t with excess fiber length. For example, after the fibers 224 dc , 224 t have been fused together, the fibers 224 dc , 224 t are pulled taut and the retention block 258 is positioned against the outer jacket 230 of the distribution cable 220 (see FIG. 47 ). The retention block 258 is then slid a distance X along the distribution cable 220 to the position of FIG. 48 . With the retention block 258 in the position of FIG. 48 , and adequate amount of excess slack/excess fiber length has been provided to the fibers 224 dc , 224 t .
- a securement structure 297 e.g., a band, strap, clamp or other type of structure
- the remainder of the mid-span breakout assembly 240 can be assembled over the mid-span breakout location 241 .
- an example minimum bend radius R m is ten times the outer diameter of the distribution cable 220 .
- R dc equals the outer radius of the distribution cable measured from the centerline to the outer surface of the outer jacket.
- R dc provides a value that is representative of the distance between the fibers 224 dc , 224 t and the centerline of the distribution cable.
- the angle of the bend is represented in a in degrees. For a 90° bend, the excess fiber length equals at least ⁇ R dc /2. For a 180° bend, the excess fiber length equals ⁇ R dc .
- a portion of the outer jacket 266 is stripped away to expose the central buffer tube 262 and the strength members 264 (see FIG. 50 ). As shown at FIG. 50 , the central buffer tube 262 and the strength members 264 project outwardly beyond an end 271 of the outer jacket 266 . As shown at FIG. 50 , the strength layer 265 has been removed from around the buffer tube 262 . After removing the end portion of the outer jacket 266 , the strength members 264 are trimmed as shown at FIG. 51 , and an end portion of the central buffer tube 262 is removed to expose the fibers 224 t .
- the tether 242 is then mounted to the base 280 of the retention block 258 .
- the jacketed end 271 of the tether 242 is inserted into the retention sleeve 294 .
- the strength members 264 are positioned within the side grooves 300 a of the base 280
- the central buffer tube 262 is inserted within the central groove 298 a of the base 280 .
- the central buffer tube 262 has a length that extends beyond the first end 284 of the base 280 , and the strength members 264 have lengths that terminate generally at the first end of the base 280 .
- a portion of the outer jacket 230 is first stripped away to provide a stripped region 400 having an upstream end 402 and a downstream end 404 . Portions of a cable netting can then be removed adjacent the upstream and downstream ends 402 , 404 so that the buffer tubes 222 are exposed.
- the outer strength member 228 can also be displaced (e.g., bunched at the bottom side of the cable) adjacent the ends 402 , 404 to facilitate accessing the buffer tubes 222 .
- Tape 406 can be used to prevent the intermediate length of netting that remains at the mid-span breakout location 241 from unraveling.
- One of the buffer tubes 222 is then selected and a first window 408 is cut into the buffer tube adjacent the upstream end 402 of the stripped region 400 and a second window 410 is cut into the buffer tube 220 adjacent the downstream end 404 of the stripped region 400 .
- the fibers 224 dc desired to be broken out are then accessed and severed at the second window 410 .
- the fibers 224 dc are pulled from the buffer tube 222 through the first window 408 (see FIG. 52 ). With the distribution cable 220 prepared as shown in FIG. 52 , the fibers 224 dc are ready to be terminated to the prepared tether 242 of FIG. 51 .
- the splice sleeve 246 and the two stiffeners 250 1 , 250 2 are first slid over the fibers 224 t of the tether and up against the retention block 258 .
- the stiffeners 250 1 , 250 2 and splice sleeve 246 can be configured to nest inside one another to minimize the space occupied by such components during the fusion process.
- the components can be slid up over the buffer tube 262 of the tether 242 .
- the fibers 224 t of the tether are fused to the fibers 224 dc of the distribution cable 220 .
- the splice sleeve 246 can be slid over the fusion location to protect the splice.
- the fibers are then tested to confirm that the fibers meet minimum insertion loss requirements.
- the cover 282 can be adhesively bonded to the base 280 of the retention block 258 to complete the assembly of the retention block.
- the retention block 258 is used to pull the fibers 224 dc , 224 t generally taut.
- the splice stiffener 248 is positioned beneath the location of the splice sleeve 246 to ensure that the splice sleeve 246 is generally centered relative to the splice stiffener 248 .
- the splice stiffener 248 can then be secured to the distribution cable 220 with tape.
- the splice stiffener 248 is generally centrally located between the ends 402 , 404 of the stripped region 400 of the distribution cable 220 .
- the retention block 258 is slid back along the distribution cable 220 to provide the fibers 224 dc , 224 t with sufficient excess fiber length to allow bending of the mid-span access location. The retention block 258 is then affixed to the distribution cable 220 .
- the stiffeners 250 1 , 250 2 are preferably slid along the fibers 224 dc , 224 t to their appropriate stiffening positions.
- the stiffener 250 1 is placed generally at a midpoint between the upstream end 402 of the stripped region 400 and the splice stiffener 248
- the stiffener 250 2 is positioned generally at a midpoint between the splice stiffener 248 and the downstream end 404 of the stripped region 400 .
- the protective sleeve 252 is secured over the stripped region 400 by the retention clips 243 , and the heat resistant tape 263 is wrapped around the mid-span breakout location 241 . Thereafter, the process is completed by applying the over mold 260 over the taped mid-span breakout location.
- the over mold layer functions to seal and protect the underlying components of the mid-span breakout assembly 240 .
- the distribution cable 220 can be spooled. It is preferred for the fibers 224 t of the tether to be pre-terminated to the fibers 224 dc of the distribution cable.
- Pre-terminated means that the fibers 224 t are fused or otherwise connected to the fibers 224 dc of the distribution cable 220 at the factory as part of the cable manufacturing process rather than being field terminated.
- the remainder of the mid-span breakout assembly is also preferably factory installed.
- the mid-span breakout assembly 240 ′ includes a separation block 700 located on an upstream end 402 ′ of a breakout location 241 ′ and a retention block 600 located on a downstream end 404 ′ of the breakout location 241 ′.
- the retention block 600 strengthens the mechanical interface between the tether cable 242 and the distribution cable 220 .
- the separation block 700 routes the optical fibers 224 dc accessed from the buffer tube 222 of the distribution cable 220 to the splice point with the tether cable 242 .
- a tube 800 extends from the separation block 700 to the retention block 600 .
- the tube 800 protects the spliced optical fibers 224 dc , 224 t along the length of the breakout location 241 ′.
- the retention block 600 includes a base 610 and a cover 650 between which the tether 242 extends.
- the retention block 600 has a plastic construction.
- the base 610 of the retention block 600 extends along a length A ( FIG. 56 ) from a first end 620 to a second end 622 .
- the base 610 also includes a first side 626 ( FIG. 57 ) adapted to engage the outer strength member 228 of the distribution cable 220 , and a second side 628 ( FIG. 55 ) adapted to engage the tether 242 .
- the base 610 includes a first section 605 and a second section 615 ( FIG. 56 ).
- the first section 605 of the base 610 includes side surfaces 601 , elongated along a length L, that extend from one end 622 of the base 610 to an intermediate end 621 of the base 610 .
- the second section 615 protrudes outwardly from the intermediate end 621 to the end 620 of the base 610 .
- the first side 626 of the base 610 has a channel 630 that extends along the length L of the first section 605 ( FIG. 57 ).
- the channel 630 has a transverse cross-sectional shape ( FIG. 59 ) that is curved to generally match the inner diameter of the distribution cable jacket 230 .
- the channel 630 of the base 610 is configured to couple to a stripped region of the distribution cable 220 ( FIG. 53 ).
- the channel 630 couples to the outer strength member 228 of the distribution cable.
- the outer strength member 228 includes multiple loose strands of Kevlar positioned around the buffer tubes 222 .
- the second side 628 of the first section 605 of the base 610 includes a central groove 602 and two side grooves 603 , 604 .
- the grooves 602 - 604 are generally parallel and extend along the length L of the first section 605 of the base 610 .
- a transverse cross-section of the first section 605 is shown in FIG. 59 .
- the central groove 602 is sized to receive the buffer tube 262 of the tether 242 .
- the side grooves 603 , 604 are sized to receive the strength members 264 of the tether 242 .
- the second section 615 of the base 610 includes a transition flange 612 that extends outwardly from the intermediate end 621 of the base 610 .
- the transition flange 612 has a generally U-shaped transverse cross-section.
- the transition flange 612 defines a groove 617 ( FIG. 55 ).
- the cover 650 of the retention block 600 mounts over the second side 628 of the base 610 .
- the cover 650 includes a first section 655 and a second section 665 .
- the cover 650 also includes a first side 676 ( FIG. 61 ) and a grooved side 678 ( FIG. 62 ).
- the first side 676 of the first section 655 includes a curved top surface 651 extending from the intermediate end 671 to the first end 672 .
- a transition flange 662 having a generally U-shaped transverse cross-section extends outwardly from the intermediate end 671 to a second end 670 .
- the grooved side 678 of the first section 655 of the cover 650 includes a central groove 652 and two side grooves 653 , 654 .
- the cover 650 is mounted onto the base 610 to align the central groove 652 of the cover 650 with the central groove 602 of the base 610 , and to align the side grooves 653 , 654 of the cover 650 with the side grooves 603 , 604 of the base 610 .
- the buffer tube 262 of the tether 242 is captured within the central grooves 602 , 652
- the strength members 264 of the tether 242 are captured within the side grooves 603 , 653 , 604 , 654 ( FIG. 67 ).
- An adhesive can be applied between the cover 650 and the base 610 to securely affix the tether 242 to the retention block 600 .
- the adhesive is applied to the second side 628 of the base 610 , the grooved side 678 of the cover 650 , the buffer tube 262 of the tether 242 , and the strength members 264 of the tether 242 .
- the retention block 600 also includes structures for facilitating aligning the cover 650 on the base 610 .
- the retention block 600 can include mating posts 668 and surface depressions (e.g., grooves, slots, cuts, notches, indentations) 608 provided on the cover 650 and the base 610 .
- the posts 668 fit within the notches 608 to maintain alignment between the base 610 and the cover 650 during assembly.
- mating posts 668 protrude downwardly from the cover 650 to engage with slots 608 on the side surfaces 601 of the base 610 .
- other suitable alignment members could also be used.
- a portion of the outer jacket 266 of the tether cable 242 is stripped away to expose the central buffer tube 262 and the strength members 264 .
- the central buffer tube 262 and the strength members 264 project outwardly beyond an end 271 of the outer jacket 266 .
- the strength layer 265 has been displaced from around the buffer tube 262 .
- the strength members 264 are trimmed as shown at FIG. 67 , and an end portion of the central buffer tube 262 is removed to expose the fibers 224 t .
- the tether 242 is then mounted to the base 610 of the retention block 600 .
- the strength members 264 are positioned within the side grooves 603 , 604 of the base 610 , and the central buffer tube 262 is inserted within the central groove 602 of the base 610 .
- the central buffer tube 262 has a length that extends beyond the intermediate end 621 of the base 610 , and the strength members 264 have lengths that terminate generally at the intermediate end 621 of the base 610 .
- the central buffer tube 262 extends beyond the end 620 of the retention block 600 . In other embodiments, however, the central buffer tube 262 terminates between the intermediate end 621 and end 620 .
- a separation block 700 provides support for transitioning fibers 224 d , from the distribution cable 220 to a fusion location.
- the separation block 700 includes a Y-shaped housing 701 defining a first opening 711 on an upstream end of the separation block 700 , a second opening 712 on a downstream end of the separation block, and a third opening 714 also located on the downstream end.
- a generally tubular section 716 of the housing 701 forms the first opening 711 and generally tubular sections 718 , 719 of the housing 701 form the second and third openings 712 , 714 .
- the second opening 712 is generally aligned with the first opening 711 to form a first channel 715 ( FIGS. 71 and 76 ).
- the third opening 714 leads to a second channel 717 (see FIGS. 71 and 76 ) that joins with the first channel 715 at the tubular section 716 of the housing 701 .
- Tubular sections 716 , 718 forming the first channel 715 are sized and shaped to enclose the buffer tubes 222 and central strength member 226 of the distribution cable 220 .
- Tubular section 719 forming the second channel 717 is sized and shaped to fit within the tube 800 and to enclose the fibers 224 dc accessed from the distribution cable 220 for splicing with the fibers 224 t of the tether cable 242 .
- the separation block 700 is formed from a first section 710 and a second section 750 .
- the first and second sections 710 , 750 each include grooves 715 a , 715 b that align and combine to form the channel 715 .
- aligning and combining grooves 717 a , 717 b forms the channel 717 .
- a protruding section 720 a defines the grooves 715 a , 717 a and a protruding section 720 b defines the grooves 715 b , 717 b.
- the first and second sections 710 , 750 are fastened together with complementary surface depressions 722 and protrusions 724 ( FIGS. 70 and 75 ).
- the protruding section 720 a on the first section 710 defines a hole 722 and the protruding section 720 b on the second section 750 includes a protrusion 724 sized to fit within the hold 722 .
- Adhesive can also be used to secure the first section 710 to the second section 750 .
- the mid-span breakout location on the distribution cable 220 can be prepared in a similar manner to the preparation discussed above with respect to FIG. 52 .
- a portion of the outer jacket 230 of the distribution cable 220 is first stripped away to provide a stripped region 400 ′ ( FIG. 53 ).
- One of the buffer tubes 222 is selected and a first window 408 ′ and a second window are cut into the selected buffer tube 222 .
- the fibers 224 dc desired to be broken out are then accessed, severed, and pulled from the buffer tube 222 through the first window 408 ′.
- the severed fibers 224 dc are ready to be fused with the tether fibers 224 t .
- the splice sleeve 246 and the tube 800 ( FIG. 53 ) are first slid over the fibers 224 t of the tether 242 , and the tube 800 is further slid up over the tether jacket 266 . With the splice sleeve 246 and tube 800 mounted on the tether 242 , the fibers 224 t of the tether are fused to the fibers 224 dc of the distribution cable 220 . The fibers are then tested to confirm that the fibers meet minimum insertion loss requirements.
- the splice sleeve 246 can be slid over the fusion location to protect the splice.
- the splice sleeve 246 has a length of less than 40 mm.
- the splice sleeve 246 has a length of less than 35 mm.
- the splice sleeve 246 has a length of about 30 mm. Decreasing the length of the splice sleeve 246 increases the degree to which the mid-span breakout assembly can bend. Increasing the flexibility of the breakout assembly 240 , 240 ′ facilitates wrapping the distribution cable 220 having the breakout assembly 240 , 240 ′ around a spool.
- the tube 800 can be slid over the splice sleeve 246 and the fusion location to protect the spliced fibers 224 dc , 224 t .
- the separation block 700 can then be added to the upstream location 402 ′ of the stripped portion 400 ′ of the distribution cable 220 .
- the buffer tubes 222 are routed through the first channel 715 of the separation block 700 and the severed fibers 224 dc are routed through the second channel 717 of the separation block 700 ( FIG. 80 ).
- the buffer tubes 222 are laid within the first groove 715 a of the first section 710 of the separation block 700 and the fibers 224 dc are laid within the second groove 717 a of the first section 710 as shown in FIG. 79 .
- the second section 750 of the separation block 700 can be secured to the first section as discussed above.
- the separation block 700 does not enclose the outer strength member 228 .
- the outer strength member 228 can be redistributed uniformly about the buffer tubes 222 of the distribution cable 220 at the upstream and downstream ends 402 ′, 404 ′ after installing the separation block 700 . In such embodiments, the outer strength member 228 extends across the breakout location 241 ′.
- the tube 800 can be slid onto section 719 of the separation block 700 .
- the tube 800 can optionally be taped or otherwise temporarily secured to the separation block 700 .
- the tube 800 is permanently secured to the separation block 700 with adhesive.
- the tube 800 is not secured to the separation block 700 .
- the retention block 600 is then mounted to the tether cable 242 .
- the retention block 600 is preferably positioned so that one end of the tube 800 is slid over the transition flanges 612 , 662 of the retention block 600 and the other end of the tube 800 remains over section 719 of the separation block 700 .
- the tube 800 has an appropriate length to provide the fibers 224 dc , 224 t with sufficient excess fiber length to allow bending of the mid-span access location 241 ′.
- the retention block 600 is then affixed to the distribution cable 220 .
- the groove 630 of the base 610 of the retention block is affixed (e.g., with adhesive) to the outer strength member 228 wrapped around the distribution cable 220 .
- the heat resistant tape/foil can be wrapped around the mid-span breakout location 241 ′. Thereafter, the process is completed by applying an over mold 260 ′ over the mid-span breakout location 241 ′.
- the over mold layer 260 ′ functions to seal and protect the underlying components of the mid-span breakout assembly 240 ′.
- the distribution cable 220 can be spooled. It is preferred for the fibers 224 t of the tether to be pre-terminated to the fibers 224 dc of the distribution cable.
- the remainder of the mid-span breakout assembly 240 ′ is also preferably factory installed.
- the term “fiber access location” can be any type of location where a fiber can be routed out of a buffer tube.
- Example fiber access locations include windows, ring cut regions, or other openings in a buffer tube.
- the fibers 224 dc , 224 t can collectively be referred to as an optical fiber structure.
- the optical fiber structure includes a first length of optical fiber within the distribution cable, a second length of optical fiber that extends through the breakout location and a third length of optical fiber that extends through the tether.
- the first, second and third lengths are in optical communication with one another so as to define a signal path that extends from the distribution cable, through the breakout location, to the end of the tether.
- optical fiber structure also includes lengths of optical fibers that do not include intermediate splices.
- breakout portions of optical fiber include portions of optical fiber that extend along the length of a breakout location.
Abstract
A telecommunications cable includes a distribution cable, a tether that branches from the distribution cable, and a tether retention block affixed to the distribution cable. The tether retention block includes a first portion and a second portion that is configured to cooperate with the first portion to secure a tether buffer tube and a strength member of the tether. Each of the first and second portions defines at least a first half-channel configured to cooperate with the first half-channel of the other portion to receive the strength member of the tether.
Description
- This application is a continuation of application Ser. No. 12/008,092, filed Jan. 7, 2008, which is a continuation of application Ser. No. 11/491,336, filed Jul. 21, 2006, now U.S. Pat. No. 7,317,863, which claims priority from provisional application Ser. No. 60/781,280, entitled FIBER OPTIC CABLE BREAKOUT CONFIGURATION, filed Mar. 9, 2006, which applications are incorporated herein by reference in their entirety.
- The principles disclosed herein relate to fiber optic cable systems. More particularly, the present disclosure relates to fiber optic cable systems having main cables and branch cables.
- Passive optical networks are becoming prevalent in part because service providers want to deliver high bandwidth communication capabilities to customers. Passive optical networks are a desirable choice for delivering high-speed communication data because they may not employ active electronic devices, such as amplifiers and repeaters, between a central office and a subscriber termination. The absence of active electronic devices may decrease network complexity and/or cost and may increase network reliability.
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FIG. 1 illustrates anetwork 100 deploying passive fiber optic lines. As shown inFIG. 1 , thenetwork 100 may include acentral office 110 that connects a number of end subscribers 115 (also calledend users 115 herein) in a network. Thecentral office 110 may additionally connect to a larger network such as the Internet (not shown) and a public switched telephone network (PSTN). Thenetwork 100 may also include fiber distribution hubs (FDHs) 130 having one or more optical splitters (e.g., 1-to-8 splitters, 1-to-16 splitters, or 1-to-32 splitters) that generate a number of individual fibers that may lead to the premises of anend user 115. The various lines of the network can be aerial or housed within underground conduits (e.g., see conduit 105). - The portion of
network 100 that is closest tocentral office 110 is generally referred to as the F1 region, where F1 is the “feeder fiber” from the central office. The F1 portion of the network may include a distribution cable having on the order of 12 to 48 fibers; however, alternative implementations may include fewer or more fibers. The portion ofnetwork 100 that includes an FDH 130 and a number ofend users 115 may be referred to as an F2 portion ofnetwork 100. Splitters used in an FDH 130 may accept a feeder cable having a number of fibers and may split those incoming fibers into, for example, 216 to 432 individual distribution fibers that may be associated with a like number of end user locations. - Referring to
FIG. 1 , thenetwork 100 includes a plurality ofbreakout locations 125 at which branch cables (e.g., drop cables, stub cables, etc.) are separated out from main cables (e.g., distribution cables). Breakout locations can also be referred to as tap locations or branch locations and branch cables can also be referred to as breakout cables. At a breakout location, fibers of the branch cables are typically spliced to selected fibers of the main cable. However, for certain applications, the interface between the fibers of the main cable and the fibers of the branch cables can be connectorized. - Stub cables are typically branch cables that are routed from breakout locations to intermediate access locations such as a pedestals, drop terminals or hubs. Intermediate access locations can provide connector interfaces located between breakout locations and subscriber locations. A drop cable is a cable that typically forms the last leg to a subscriber location. For example, drop cables are routed from intermediate access locations to subscriber locations. Drop cables can also be routed directly from breakout locations to subscriber locations hereby bypassing any intermediate access locations
- Branch cables can manually be separated out from a main cable in the field using field splices. Field splices are typically housed within sealed splice enclosures. Manual splicing in the field is time consuming and expensive.
- As an alternative to manual splicing in the field, pre-terminated cable systems have been developed. Pre-terminated cable systems include factory integrated breakout locations manufactured at predetermined positions along the length of a main cable (e.g., see U.S. Pat. Nos. 4,961,623; 5,125,060; and 5,210,812). However, the installation of pre-terminated cables can be difficult. For example, for underground applications, pre-terminations can complicate passing pre-terminated cable through the underground conduit typically used to hold fiber optic cable (e.g., 1.25 inch inner diameter conduit). Similarly, for aerial applications, pre-terminations can complicate passing pre-terminated cable through aerial cable retention loops.
- Certain aspects of the disclosure relate to mid-span breakout configurations for pre-terminated fiber optic distribution cables.
- A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
-
FIG. 1 shows a prior art passive fiber optic network; -
FIG. 2 is a cross sectional view of an example distribution cable; -
FIG. 3 is a side view of a mid-span breakout location having features that are examples of inventive aspects in accordance with the principles of the present disclosure; -
FIG. 4 is a left end view of the mid-span breakout location ofFIG. 3 ; -
FIG. 5 is a right end view of the mid-span breakout location ofFIG. 3 ; -
FIG. 6 is a side view of the mid-span breakout location ofFIG. 3 with the overmold removed; -
FIG. 7 is a side view of the mid-span breakout location ofFIG. 3 with the overmold and protective sleeve removed; -
FIG. 7A is a cross sectional view taken alongsection line 7A-7A ofFIG. 7 ; -
FIG. 7B is a cross sectional view taken alongsection line 7B-7B ofFIG. 7 ; -
FIG. 8 is a cross sectional view of the tether taken along section line 8-8 ofFIG. 7 ; -
FIG. 9 is a perspective view of a base of a retention block used at the mid-span breakout location ofFIG. 3 ; -
FIG. 10 is a front side view of the base ofFIG. 9 ; -
FIG. 11 is a top view of the base ofFIG. 9 ; -
FIG. 12 is a bottom view of the base ofFIG. 9 ; -
FIG. 13 is a left end view of the base ofFIG. 9 ; -
FIG. 14 is a right end view of the base ofFIG. 9 ; -
FIG. 15 is a perspective view of a cover adapted to mount to the base ofFIG. 9 ; -
FIG. 16 is a top view of the cover ofFIG. 15 ; -
FIG. 17 is a front side view of the cover ofFIG. 15 ; -
FIG. 18 is an underside view of the cover ofFIG. 15 ; -
FIG. 19 is a right end view of the cover ofFIG. 15 ; -
FIG. 20 is a perspective view of a splice stiffener used at the mid-span breakout location ofFIG. 3 ; -
FIG. 21 is a front side view of the splice stiffener ofFIG. 20 ; -
FIG. 22 is a top view of the splice stiffener ofFIG. 20 ; -
FIG. 23 is a bottom view of the splice stiffener ofFIG. 20 ; -
FIG. 24 is a right end view of the splice stiffener ofFIG. 20 ; -
FIG. 25 is a cross sectional view taken along section line 25-25 ofFIG. 22 ; -
FIG. 26 is a cross sectional view taken along section line 26-26 ofFIG. 21 , the splice stiffener is shown mounted on a distribution cable; -
FIG. 27 is a perspective view of a stiffener used at the mid-span breakout location ofFIG. 3 ; -
FIG. 28 is a front side view of the stiffener ofFIG. 27 ; -
FIG. 29 is a cross sectional view taken along section line 29-29 ofFIG. 28 ; -
FIG. 30 is a cross sectional view taken along section line 30-30 ofFIG. 28 ; -
FIG. 31 is a perspective view of a protective sleeve used at the mid-span breakout location ofFIG. 3 ; -
FIG. 32 is a front side view of the protective sleeve ofFIG. 31 ; -
FIG. 33 is a right end view of the protective sleeve ofFIG. 31 ; -
FIG. 34 is a left end view of the protective sleeve ofFIG. 31 ; -
FIG. 35 is a top view of the protective sleeve ofFIG. 31 ; -
FIG. 36 is a cross sectional view taken along section line 36-36 ofFIG. 32 ; -
FIG. 37 is a cross sectional view taken along section line 37-37 ofFIG. 32 ; -
FIG. 38 is a perspective view of a retention clip used to retain the protective sleeve ofFIG. 31 at the mid-span breakout location ofFIG. 3 ; -
FIG. 39 is a front side view of the retention clip ofFIG. 38 ; -
FIG. 40 is a top view of the retention clip ofFIG. 38 ; -
FIG. 41 is a bottom view of the retention clip ofFIG. 38 ; -
FIG. 42 is a right end view of the retention clip ofFIG. 38 ; -
FIG. 43 is a side view of an overmold used at the mid-span breakout location ofFIG. 3 ; -
FIG. 44 is a top view of the overmold ofFIG. 43 ; -
FIG. 45 is a bottom view of the overmold ofFIG. 43 ; -
FIG. 46 is a left end view of the overmold ofFIG. 43 ; -
FIGS. 47 and 48 are schematic views showing a method for providing excess fiber length at the mid-span breakout location ofFIG. 3 ; -
FIG. 49 is a schematic view showing a distribution cable bent along a 90 degree curve at a maximum bend radius; -
FIG. 50 shows a first preparation step for a tether used at the mid-span breakout location ofFIG. 3 ; -
FIG. 51 shows a subsequent preparation step of the tether ofFIG. 50 ; and -
FIG. 52 shows an initial preparation of the distribution cable at the mid-span breakout location; -
FIG. 53 is a perspective view of an example mid-span breakout assembly; -
FIG. 54 is a perspective view of an example retention block; -
FIG. 55 is a perspective view of a base of the retention block ofFIG. 54 ; -
FIG. 56 is a top view of the base ofFIG. 55 ; -
FIG. 57 is a bottom perspective view of the base ofFIG. 55 ; -
FIG. 58 is a side view of the base ofFIG. 55 ; -
FIG. 59 is a transverse cross-sectional view of the base ofFIG. 55 ; -
FIG. 60 is a front view of the base ofFIG. 55 ; -
FIG. 61 is a top perspective view of a cover of the retention block ofFIG. 54 ; -
FIG. 62 is a bottom perspective view of the cover ofFIG. 61 ; -
FIG. 63 is a side view of the cover ofFIG. 61 ; -
FIG. 64 is a top view of the cover ofFIG. 61 ; -
FIG. 65 is a transverse cross-sectional view of the cover ofFIG. 61 ; -
FIG. 66 is a front view of the cover ofFIG. 61 ; -
FIG. 67 is a top view of the cover ofFIG. 61 showing preparation of a tether cable at an example mid-span breakout location; -
FIG. 68 is a front perspective view of an example separation block; -
FIG. 69 is a front perspective view of an example first section of the separation block ofFIG. 68 ; -
FIG. 70 is a rear perspective view of the first section ofFIG. 69 ; -
FIG. 71 is a side view of the first section ofFIG. 69 ; -
FIG. 72 is a top view of the first section ofFIG. 69 ; -
FIG. 73 is a rear view of the first section ofFIG. 69 ; -
FIG. 74 is a rear perspective view of an example second section of the separation block ofFIG. 68 ; -
FIG. 75 is a front perspective view of the second section ofFIG. 74 ; -
FIG. 76 is a side view of the second section ofFIG. 74 ; -
FIG. 77 is a top view of the second section ofFIG. 74 ; -
FIG. 78 is a cross-sectional view of the first section ofFIG. 74 ; and -
FIG. 79 is a side view of the second section ofFIG. 74 showing preparation of a distribution cable at an example mid-span breakout location. - The present disclosure relates to mid-span breakout arrangements provided on distribution cables. A typical distribution cable includes a relatively large number of fibers (e.g., 72, 144 or more fibers). The fibers are typically segregated into separate groups with each group contained within a separate buffer tube. The fibers within each buffer tube can include either ribbon fibers or loose fibers.
- For example,
FIG. 2 shows anexample distribution cable 220 including sixseparate buffer tubes 222 each containing twelvefibers 224. Thebuffer tubes 222 may be gel filled. Thedistribution cable 220 also includes acentral strength member 226 for reinforcing thecable 220, and anouter strength member 228 such as Kevlar for also reinforcing the cable. Thedistribution cable 220 further includes anouter jacket 230 that encloses thebuffer tubes 222.Ripcords 232 can be provided for facilitating tearing away portions of thejacket 230 to access thefibers 224 within thejacket 230. - While distribution cables typically have a large number of fibers, the various aspects of the present disclosure are also applicable to distribution cables having fewer numbers of fibers (e.g., 2 or more fibers). For example, the distribution cable can include an outer jacket enclosing a single buffer tube and at least two strength members extending on opposite sides of the single buffer tube. An outer strength member such as Kevlar can surround the single buffer tube within the jacket. The single buffer tube can enclose loose fibers or ribbon fibers.
- A typical mid-span breakout location is provided at an intermediate point along the length of a distribution cable. Commonly a tether (e.g., a drop cable or a stub cable) branches out from the distribution cable at the breakout location. The tether most commonly has a fewer number of fibers as compared to the number of fibers provided within the distribution cable. In an example embodiment, the tether has no more than twelve fibers. The tether includes fibers that extend between first and second ends. The first ends of the tether fibers are preferably spliced to selected fibers of the distribution cable at the breakout location. The second ends of the tether fibers can either be connectorized or unconnectorized.
-
FIGS. 3-7 illustrate a mid-spanbreakout assembly 240 having features that are examples of inventive aspects in accordance with the principles of the present disclosure. The breakout assembly is positioned at amid-span breakout location 241. As shown atFIGS. 3 , 6 and 7, atether 242 branches outwardly from amain distribution cable 220 at themid-span breakout location 241. Thebreakout location 241 is shown including asplice location 244 where selectedfibers 224 dc of the main distribution cable 220 (e.g., typically less than twelve fibers) are spliced tocorresponding fibers 224 t of thetether 242. The breakout assembly includes asplice sleeve 246 positioned over the splices, and asplice stiffener 248 for holding thesplice sleeve 246. Thebreakout assembly 240 also includes stiffeners 250 1, 250 2 between which thesplice stiffener 248 is positioned. Thefibers 224 dc from thedistribution cable 220 pass through the stiffener 250 1 to reach thesplice location 244. Thefibers 224 t from thetether 242 pass through the stiffener 250 2 to reach thesplice location 244. Thebreakout assembly 240 further includes a protective sleeve 252 (e.g., a shell) that covers thebreakout location 241. The stiffeners 250 1, 250 2 and thesplice stiffener 248 are all enclosed within thesleeve 252. Afirst end 254 of thesleeve 252 forms a tapered nose, and asecond end 256 of thesleeve 252 overlaps aretention block 258 through which thefibers 224 t of thetether 242 pass. Retention clips 243 are used to secure theprotective sleeve 252 to thedistribution cable 220. Thebreakout assembly 240 also includes an over-mold (i.e., a flexible closure) 260 that encloses and seals theprotective sleeve 252, theclips 243 and theretention block 258. In certain embodiments, a wrap of heatresistant tape 263 can provide an intermediate layer between theprotective sleeve 252 and the over-mold 260. - Referring to
FIG. 8 , thetether 242 joined to thedistribution cable 220 at thebreakout location 241 is depicted as having a flat cable configuration. The flat cable configuration includes acentral buffer tube 262 containing a plurality of fibers 224 t (e.g., typically one to twelve loose or ribbonized fibers). Strength members 264 (e.g., flexible rods formed by glass fiber reinforced epoxy) are positioned on opposite sides of thecentral buffer tube 262. Anouter jacket 266 surrounds thestrength members 264 and thebuffer tube 262. Theouter jacket 266 includes an outer perimeter having an elongated transverse cross-sectional shape. An additional strength layer 265 (e.g., Kevlar) can be positioned between thebuffer tube 262 and theouter jacket 266. As shown atFIG. 8 , the transverse cross-sectional shape includes oppositely positioned, generallyparallel sides 268 interconnected by rounded ends 270. - When the
tether 242 is secured to thedistribution cable 220, thetether 242 should preferably be able to withstand a pullout force of at least 100 pounds. To meet this pullout force requirement, theretention block 258 is used to strengthen the mechanical interface between thetether 242 and thedistribution cable 220. As shown atFIG. 7 , theretention block 258 includes a base 280 (i.e., or first portion) and a cover 282 (i.e., or second portion) between which thetether 242 extends. In one embodiment, theretention block 258 has a plastic construction. - Referring to
FIGS. 9-14 , thebase 280 of theretention block 258 includes afirst end 284 positioned opposite from asecond end 286. Thebase 280 is elongated along a length A that extends between the first and second ends 284, 286. The base also includes afirst side 288 adapted to engage the outer surface of the distribution cable jacket, and asecond side 290 adapted to engage thetether 242. Thefirst side 288 has achannel 292 that extends along the length L of thebase 280. Thechannel 292 has a transverse cross-sectional shape that is curved to match the outer diameter of thedistribution cable jacket 230. Thus, when theretention block 258 is mounted to thedistribution cable 220, thedistribution cable 220 nests within thechannel 292 as shown atFIGS. 7A and 7B . Thesecond side 290 of thebase 280 includes aretention sleeve 294 defining anelongate opening 296 having a transverse cross-sectional shape that matches the transverse cross-sectional shape of the outer perimeter of thetether cable jacket 266. When thetether 242 is secured to theretention block 258, a jacketed portion of thetether 242 fits within the sleeve 294 (seeFIG. 7A ). When the base is mounted on thedistribution cable 220, theopening 296 is elongated in a direction generally perpendicular to a radial line B that extends outwardly from the center of thedistribution cable 220. Thesecond side 290 of the base 280 also includes acentral groove 298 a and twoside grooves 300 a. Thegrooves retention block 258. Thecentral groove 298 a is sized to receive thebuffer tube 262 of thetether 242. Theside grooves 300 a are sized to receive thestrength members 264 of thetether 242. - The base 280 also includes structures for resisting axial movement between the
retention block 258 and the over-mold 260. For example, as shown atFIGS. 9-12 ,surface depressions 302 are provided adjacent thesecond end 286 of thebase 280. The surface depressions 302 (e.g., grooves, slots, cuts, notches, indentations) provide void regions for allowing over-mold material to fill-in during the over-molding process to provide a more secure connection between theretention block 258 and theouter over-mold 260. In this way, a mechanical interlock is formed that resists axial movement between theretention block 258 and the over-mold 260. In other embodiments, the base 280 can include outwardly projecting structures (e.g., flanges, bumps, ribs) that are embedded in the over-mold to further resist axial movement between the over-mold and the retention block. - The
cover 282 of theretention block 258 mounts over thesecond side 290 of the base 280 adjacent thefirst end 284 of thebase 280. As shown atFIGS. 15-19 , thecover 282 includes acentral groove 298 b and twoside grooves 300 b. When thecover 282 is mounted on thebase 280, thecentral groove 298 b aligns with thecentral groove 298 a of thebase 280, and theside grooves 300 b align with theside grooves 300 a of thebase 280. Thus, when theretention block 258 is assembled, thebuffer tube 262 of thetether 242 is captured within thecentral grooves strength members 264 of thetether 242 are captured within theside grooves FIG. 7B ). An adhesive 299 (seeFIG. 7B ) can be applied between thecover 282 and the base 280 to securely affix thetether 242 to theretention block 258. In one embodiment, the adhesive 299 is applied to thesecond side 290 of thebase 280, the grooved side of thecover 282, thebuffer tube 262 of thetether 242, and thestrength members 264 of thetether 242. - The
retention block 258 also includes structures for facilitating aligning thecover 282 on thebase 280. For example, as shown atFIG. 7B , theretention block 258 can includemating posts 304 and holes 306 provided on thecover 282 and thebase 280. Theposts 304 fit within theholes 306 to maintain alignment between the base 280 and thecover 282 during assembly. - The
retention block 258 further includes an outer band groove 308 (seeFIGS. 9 and 15 ) that extends around at least a portion of the perimeter of theretention block 258. Theband groove 308 is sized to receive a strap or band 297 (seeFIG. 7 ) that is wrapped around theretention block 258 and thedistribution cable 220 to secure theretention block 258 to thedistribution cable 258. The band can also function to assist in holding thecover 282 on thebase 280. - The
splice stiffener 248 of thebreakout assembly 240 preferably has a crush-resistant construction adapted to prevent the splices of thebreakout location 241 from being damaged. In one embodiment, thesplice stiffener 248 is made of a plastic material. As shown atFIGS. 20-26 , thesplice stiffener 248 includes anelongated base portion 320 having a generally half-cylinder shape. Thebase portion 320 includes first andsecond sides first side 322 of thebase portion 320 includes aconcave surface 325 defining achannel 326 having an open side. When thesplice stiffener 248 is mounted at thebreakout location 241, theconcave surface 325 is adapted to face toward thebuffer tubes 222 of thedistribution cable 220. As shown in the cross-sectional view ofFIG. 26 , theconcave surface 325 has a semi-circular shape having a curvature that generally matches an outer diameter D circumscribing thebuffer tubes 322 of thedistribution cable 320. Theconcave surface 325 is shown covering approximately one half the diameter D, and a plurality of thebuffer tubes 222 are shown positioned within thechannel 326. Depending upon how the break-out location is prepared (i.e., whether or not theouter strength members 228 of thedistribution cable 220 have been removed), the layer formed by thestrength members 228 may be positioned between thesurface 325 and thebuffer tubes 222. - The
splice stiffener 248 also includes a pair ofparallel retaining members 328 that project outwardly from thesecond side 324 of thebase portion 320. Asplice retention channel 330 having an open side is defined between the retainingmembers 328. Abed 332 of thechannel 330 is generally planar. Splice sleeve retention ridges orshoulders 334 project outwardly from thebed 332 adjacent opposite ends of thechannel 330. Snap fit tabs 336 project laterally into thechannel 330 from the retainingmembers 328. In use, thesplice sleeve 246 is snap fit between the tabs 336 and into thechannel 330. Once thesplice sleeve 246 is in thesplice retention channel 330, the tabs 336 prevent thesplice sleeve 246 from unintentionally exiting thesplice retention channel 330 through the open side. Also, the retention shoulders 334 prevent thesplice sleeve 246 from sliding out of thesplice retention channel 330 through the ends of thesplice retention channel 330. Preferably, thesplice sleeve 246 is free to slide back and forth between theshoulders 334 within thechannel 330. - The stiffeners 250 1, 250 2 of the
breakout assembly 240 are preferably configured to provide increased crush resistance to theprotective sleeve 252. In certain embodiments, the stiffeners 250 1, 250 2 have a stiffer construction than theprotective sleeve 252 and are made of a plastic material. Referring toFIGS. 27-30 , the stiffeners 250 1, 250 2 have a generally tubular configuration and each define a through-passage 340 for receiving theirrespective fibers passages 340 preferably have large enough cross-sectional areas to allow thefibers breakout location 241 is bent.Ends 342 of thepassages 340 preferably include contours that extend around the perimeter of thepassages 340 for preventing the fibers from being bent beyond acceptable bend radius requirements. - Referring to
FIG. 30 , the stiffeners 250 1, 250 2 each include abase portion 344 spaced from anarcuate dome portion 346. The stiffeners 250 1, 250 2 each also include a pair of planar, generallyparallel side walls 348 that connect thebase portion 344 to thedome portion 346. Thebase portions 344 defineconcave channels 350 adapted to receivebuffer tubes 222 of thedistribution cable 220 when the stiffeners 250 1, 250 2 are positioned at thebreakout location 241. Thesidewalls 348 and thedome portion 346 define an exterior shape that generally matches the interior shape of theprotective sleeve 252. - The
protective sleeve 252 of themid-span breakout assembly 240 is adapted to form a protective shell over thebreakout location 241. Theprotective sleeve 252 is preferably sufficiently flexible to allow the pre-terminated cable (i.e., thedistribution cable 220 with the tethers terminated 242 thereto) to be readily stored on a spool. Thestiffeners 248, 250 1, 250 2 provide regions/segments of increased crush resistance separated by regions/segments of increased flexibility. - Referring to
FIGS. 31-37 , theprotective sleeve 252 is elongated along a length that extends between thefirst end 254 and thesecond end 256 and has a generally U-shaped transverse cross section forming a channel 360 (seeFIG. 36 ) with an open side sized to be inserted over the distribution cable. Thechannel 360 has a cross sectional shape sized to conform generally with the outer cross sectional shape of the stiffeners 250 1, 250 2. Preferably, the internal transverse cross sectional shape of thechannel 360 is sized to accommodate sufficient slack or excess fiber length to allow thebreakout location 241 to be bent without negatively affecting performance or damaging the fibers of the breakout location. Thechannel 360 of theprotective sleeve 252 is defined between opposingsidewalls 362 definingopenings 364 for receiving snap-fit tabs 366 of the retention clips 243. Thesidewalls 362 are interconnected by acurved portion 363. - The
first end 254 of theprotective sleeve 252 includes alow profile portion 365 that fits closely to thedistribution cable 220. Thelow profile portion 365 includes achannel 367 that receives theouter jacket 230 of thedistribution cable 220. Thechannel 367 has a diameter that generally matches the outer diameter of thedistribution cable 220. Thefirst end 254 also includes atransition portion 369 that provides a smooth taper/contour between thelow profile portion 365 and a main body of theprotective sleeve 252. Thelow profile portion 365 and thetransition portion 369 cooperate to provide a smooth transition from thedistribution cable 220 to the main outer surface of theprotective sleeve 252. The smooth taper provided by the first end (i.e., the leading end/nose) of theprotective sleeve 252 assists in pulling the cable through underground conduit without snagging thebreakout location 241. Thesecond end 256 of theprotective sleeve 252 forms anenlarged receptacle 372 sized sufficiently large to receive theretention block 258. A taperedtransition portion 370 is provided between the main body of theprotective sleeve 252 and theenlarged receptacle 372. When thesleeve 252 is mounted on thedistribution cable 220, thelow profile portion 365 overlaps thejacket 230 at the upstream end of the breakout location and theenlarged receptacle 372 overlaps the retention block adjacent the downstream end of the breakout location. - As shown at
FIGS. 38-42 , the retention clips 243 of themid-span breakout assembly 240 includecurved portions 380 that receive thedistribution cable 220 on the opposite side of theprotective sleeve 252 such that thedistribution cable 220 is captured between theclips 243 and theprotective sleeve 252. Theclips 243 also includestraight extensions 382 that project upwardly from thecurved portion 380. Theextensions 382 of theclips 243 fit inside theprotective sleeve 252 and assist in preventingfibers protective sleeve 252 and thedistribution cable 220 or theclips 243. Theextensions 382 include snap-fit tabs 366 that fit within theopenings 364 of theprotective sleeve 252. Theclips 243 also includediscrete stops 384 for engaging bottom edges of theprotection sleeve 252. Thestops 384 are located at the exteriors of theclips 343 and project outwardly from thecurved portions 380. - The
over-mold 260 of themid-span breakout assembly 240 is preferably made of a polymer plastic material. As shown atFIGS. 43-46 , the over-mold 260 has aprimary contour 390 at a leading edge configured to coincide generally with the contour of the leading end of theprotective sleeve 252. A trailingend 392 of the over-mold 260 is also slightly contoured. The transverse cross sectional shape of the over-mold includes first and secondcurved portions planar portions - It is preferred for the over-mold 360 to be sized with a cross sectional shape sufficient to allow the breakout location to be readily passed through a one and one-half inch inner diameter conduit or a one and one-quarter inch diameter conduit. In certain embodiments, the breakout location has a cross sectional area that can be passed through a one inch inner diameter conduit.
- The
mid-span breakout location 241 is preferably configured to allow the mid-span breakout location to be bent/flexed in any orientation without damaging thefibers fibers fibers mid-span breakout location 241 are provided with at least 2% excess fiber length. In other embodiments, thefibers fibers mid-span breakout location 241 is about 32 centimeters and about 1 centimeter of excess fiber length is provided to thefibers mid-span breakout location 241. - When the
mid-span breakout assembly 240 is assembled, measures are taken to provide thefibers fibers fibers retention block 258 is positioned against theouter jacket 230 of the distribution cable 220 (seeFIG. 47 ). Theretention block 258 is then slid a distance X along thedistribution cable 220 to the position ofFIG. 48 . With theretention block 258 in the position ofFIG. 48 , and adequate amount of excess slack/excess fiber length has been provided to thefibers retention block 258 is in the position ofFIG. 48 , a securement structure 297 (e.g., a band, strap, clamp or other type of structure) is used to fix theretention block 258 in position relative to thedistribution cable 220. Thereafter, the remainder of themid-span breakout assembly 240 can be assembled over themid-span breakout location 241. - In determining the amount of excess fiber length to be provided at the
mid-span breakout location 241, it is desirable for thedistribution cable 220 to be able to be bent in a minimum bend radius Rm in any orientation without compromising themid-span breakout assembly 240. In one embodiment, an example minimum bend radius Rm is ten times the outer diameter of thedistribution cable 220. When the distribution cable is flexed to a bend having a radius Rm as shown atFIG. 49 , aportion 500 of thedistribution cable 220 at the outside of the curve elongates and a portion 501 of the distribution cable at the inside of the curve shortens. The centerline of the distribution cable does not change in length. Taking the above factors into consideration, the amount of slack fiber length required to accommodate the elongation at theouter portion 500 of the bend can be calculated by the following formula: -
- In the above formula, where Rdc equals the outer radius of the distribution cable measured from the centerline to the outer surface of the outer jacket. Rdc provides a value that is representative of the distance between the
fibers - To prepare the
tether 242 to be incorporated into themid-span breakout assembly 240, a portion of theouter jacket 266 is stripped away to expose thecentral buffer tube 262 and the strength members 264 (seeFIG. 50 ). As shown atFIG. 50 , thecentral buffer tube 262 and thestrength members 264 project outwardly beyond anend 271 of theouter jacket 266. As shown atFIG. 50 , thestrength layer 265 has been removed from around thebuffer tube 262. After removing the end portion of theouter jacket 266, thestrength members 264 are trimmed as shown atFIG. 51 , and an end portion of thecentral buffer tube 262 is removed to expose thefibers 224 t. Thetether 242 is then mounted to thebase 280 of theretention block 258. For example, as shown atFIG. 51 , thejacketed end 271 of thetether 242 is inserted into theretention sleeve 294. Also, thestrength members 264 are positioned within theside grooves 300 a of thebase 280, and thecentral buffer tube 262 is inserted within thecentral groove 298 a of thebase 280. As shown inFIG. 51 , thecentral buffer tube 262 has a length that extends beyond thefirst end 284 of thebase 280, and thestrength members 264 have lengths that terminate generally at the first end of thebase 280. - To prepare the mid-span breakout location on the
distribution cable 220, a portion of theouter jacket 230 is first stripped away to provide a strippedregion 400 having anupstream end 402 and adownstream end 404. Portions of a cable netting can then be removed adjacent the upstream and downstream ends 402, 404 so that thebuffer tubes 222 are exposed. Theouter strength member 228 can also be displaced (e.g., bunched at the bottom side of the cable) adjacent theends buffer tubes 222.Tape 406 can be used to prevent the intermediate length of netting that remains at themid-span breakout location 241 from unraveling. One of thebuffer tubes 222 is then selected and afirst window 408 is cut into the buffer tube adjacent theupstream end 402 of the strippedregion 400 and asecond window 410 is cut into thebuffer tube 220 adjacent thedownstream end 404 of the strippedregion 400. Thefibers 224 dc desired to be broken out are then accessed and severed at thesecond window 410. After thefibers 224 dc have been severed, thefibers 224 dc are pulled from thebuffer tube 222 through the first window 408 (seeFIG. 52 ). With thedistribution cable 220 prepared as shown inFIG. 52 , thefibers 224 dc are ready to be terminated to theprepared tether 242 ofFIG. 51 . - To connect the
tether 242 to thefibers 224 dc, thesplice sleeve 246 and the two stiffeners 250 1, 250 2 are first slid over thefibers 224 t of the tether and up against theretention block 258. In certain embodiments, the stiffeners 250 1, 250 2 andsplice sleeve 246 can be configured to nest inside one another to minimize the space occupied by such components during the fusion process. In certain embodiments, the components can be slid up over thebuffer tube 262 of thetether 242. With the stiffeners 250 1, 250 2 and thesplice sleeve 246 mounted on thetether 242, thefibers 224 t of the tether are fused to thefibers 224 dc of thedistribution cable 220. After the fusion process is complete, thesplice sleeve 246 can be slid over the fusion location to protect the splice. The fibers are then tested to confirm that the fibers meet minimum insertion loss requirements. After verifying insertion loss, thecover 282 can be adhesively bonded to thebase 280 of theretention block 258 to complete the assembly of the retention block. - Once the
retention block 258 has been assembled, theretention block 258 is used to pull thefibers fibers splice stiffener 248 is positioned beneath the location of thesplice sleeve 246 to ensure that thesplice sleeve 246 is generally centered relative to thesplice stiffener 248. Thesplice stiffener 248 can then be secured to thedistribution cable 220 with tape. Preferably, thesplice stiffener 248 is generally centrally located between theends region 400 of thedistribution cable 220. - After the positioning of the
splice stiffener 248 has been determined, theretention block 258 is slid back along thedistribution cable 220 to provide thefibers retention block 258 is then affixed to thedistribution cable 220. - Once the
retention block 258 has been affixed to thedistribution cable 220, the stiffeners 250 1, 250 2 are preferably slid along thefibers upstream end 402 of the strippedregion 400 and thesplice stiffener 248, and the stiffener 250 2 is positioned generally at a midpoint between thesplice stiffener 248 and thedownstream end 404 of the strippedregion 400. Once the stiffeners 250 1, 250 2 are in position, thesplice sleeve 246 can be snapped within thesplice stiffener 248. - To finalize the assembly process, the
protective sleeve 252 is secured over the strippedregion 400 by the retention clips 243, and the heatresistant tape 263 is wrapped around themid-span breakout location 241. Thereafter, the process is completed by applying the overmold 260 over the taped mid-span breakout location. The over mold layer functions to seal and protect the underlying components of themid-span breakout assembly 240. Thereafter, thedistribution cable 220 can be spooled. It is preferred for thefibers 224 t of the tether to be pre-terminated to thefibers 224 dc of the distribution cable. “Pre-terminated” means that thefibers 224 t are fused or otherwise connected to thefibers 224 dc of thedistribution cable 220 at the factory as part of the cable manufacturing process rather than being field terminated. The remainder of the mid-span breakout assembly is also preferably factory installed. - Referring now to
FIGS. 53-79 , another example embodiment a mid-spanbreakout assembly 240′ is shown having features that are examples of inventive aspects in accordance with the principles of the present disclosure. Themid-span breakout assembly 240′ includes aseparation block 700 located on anupstream end 402′ of abreakout location 241′ and aretention block 600 located on adownstream end 404′ of thebreakout location 241′. Theretention block 600 strengthens the mechanical interface between thetether cable 242 and thedistribution cable 220. Theseparation block 700 routes theoptical fibers 224 dc accessed from thebuffer tube 222 of thedistribution cable 220 to the splice point with thetether cable 242. Atube 800 extends from theseparation block 700 to theretention block 600. Thetube 800 protects the splicedoptical fibers breakout location 241′. - As shown in
FIG. 54 , theretention block 600 includes abase 610 and acover 650 between which thetether 242 extends. In one embodiment, theretention block 600 has a plastic construction. Referring toFIGS. 55-60 , thebase 610 of theretention block 600 extends along a length A (FIG. 56 ) from afirst end 620 to asecond end 622. The base 610 also includes a first side 626 (FIG. 57 ) adapted to engage theouter strength member 228 of thedistribution cable 220, and a second side 628 (FIG. 55 ) adapted to engage thetether 242. Thebase 610 includes afirst section 605 and a second section 615 (FIG. 56 ). Thefirst section 605 of thebase 610 includes side surfaces 601, elongated along a length L, that extend from oneend 622 of the base 610 to anintermediate end 621 of thebase 610. Thesecond section 615 protrudes outwardly from theintermediate end 621 to theend 620 of thebase 610. - The
first side 626 of thebase 610 has achannel 630 that extends along the length L of the first section 605 (FIG. 57 ). In some embodiments, thechannel 630 has a transverse cross-sectional shape (FIG. 59 ) that is curved to generally match the inner diameter of thedistribution cable jacket 230. Thechannel 630 of thebase 610 is configured to couple to a stripped region of the distribution cable 220 (FIG. 53 ). In some embodiments, thechannel 630 couples to theouter strength member 228 of the distribution cable. In one example embodiment, theouter strength member 228 includes multiple loose strands of Kevlar positioned around thebuffer tubes 222. Thus, when theretention block 600 is mounted to theouter strength member 228, theouter strength member 228 and thebuffer tubes 222 of thedistribution cable 220 nest within thechannel 630. - The
second side 628 of thefirst section 605 of thebase 610 includes acentral groove 602 and twoside grooves first section 605 of thebase 610. A transverse cross-section of thefirst section 605 is shown inFIG. 59 . Thecentral groove 602 is sized to receive thebuffer tube 262 of thetether 242. Theside grooves strength members 264 of thetether 242. - The
second section 615 of thebase 610 includes atransition flange 612 that extends outwardly from theintermediate end 621 of thebase 610. In some embodiments, thetransition flange 612 has a generally U-shaped transverse cross-section. In one embodiment, thetransition flange 612 defines a groove 617 (FIG. 55 ). - The
cover 650 of theretention block 600 mounts over thesecond side 628 of thebase 610. As shown atFIG. 64 , thecover 650 includes afirst section 655 and asecond section 665. Thecover 650 also includes a first side 676 (FIG. 61 ) and a grooved side 678 (FIG. 62 ). Thefirst side 676 of thefirst section 655 includes a curvedtop surface 651 extending from theintermediate end 671 to thefirst end 672. Atransition flange 662 having a generally U-shaped transverse cross-section extends outwardly from theintermediate end 671 to asecond end 670. Thegrooved side 678 of thefirst section 655 of thecover 650 includes acentral groove 652 and twoside grooves - In use, the
cover 650 is mounted onto the base 610 to align thecentral groove 652 of thecover 650 with thecentral groove 602 of thebase 610, and to align theside grooves cover 650 with theside grooves base 610. Thus, when theretention block 600 is assembled, thebuffer tube 262 of thetether 242 is captured within thecentral grooves strength members 264 of thetether 242 are captured within theside grooves FIG. 67 ). An adhesive can be applied between thecover 650 and the base 610 to securely affix thetether 242 to theretention block 600. In one embodiment, the adhesive is applied to thesecond side 628 of thebase 610, thegrooved side 678 of thecover 650, thebuffer tube 262 of thetether 242, and thestrength members 264 of thetether 242. - In some embodiments, the
retention block 600 also includes structures for facilitating aligning thecover 650 on thebase 610. For example, as shown atFIGS. 55 and 62 , theretention block 600 can includemating posts 668 and surface depressions (e.g., grooves, slots, cuts, notches, indentations) 608 provided on thecover 650 and thebase 610. Theposts 668 fit within thenotches 608 to maintain alignment between the base 610 and thecover 650 during assembly. For example, in the embodiment shown, mating posts 668 protrude downwardly from thecover 650 to engage withslots 608 on the side surfaces 601 of thebase 610. In other embodiments, however, other suitable alignment members could also be used. - Referring now to
FIG. 67 , to prepare thetether 242 to be incorporated into themid-span breakout assembly 240′, a portion of theouter jacket 266 of thetether cable 242 is stripped away to expose thecentral buffer tube 262 and thestrength members 264. As shown atFIG. 67 , thecentral buffer tube 262 and thestrength members 264 project outwardly beyond anend 271 of theouter jacket 266. Thestrength layer 265 has been displaced from around thebuffer tube 262. After removing the end portion of theouter jacket 266, thestrength members 264 are trimmed as shown atFIG. 67 , and an end portion of thecentral buffer tube 262 is removed to expose thefibers 224 t. - The
tether 242 is then mounted to thebase 610 of theretention block 600. For example, as shown atFIG. 67 , thestrength members 264 are positioned within theside grooves base 610, and thecentral buffer tube 262 is inserted within thecentral groove 602 of thebase 610. Thecentral buffer tube 262 has a length that extends beyond theintermediate end 621 of thebase 610, and thestrength members 264 have lengths that terminate generally at theintermediate end 621 of thebase 610. In some embodiments, thecentral buffer tube 262 extends beyond theend 620 of theretention block 600. In other embodiments, however, thecentral buffer tube 262 terminates between theintermediate end 621 and end 620. - Referring now to
FIGS. 68-80 , aseparation block 700 provides support for transitioningfibers 224 d, from thedistribution cable 220 to a fusion location. As shown inFIG. 68 , theseparation block 700 includes a Y-shapedhousing 701 defining afirst opening 711 on an upstream end of theseparation block 700, asecond opening 712 on a downstream end of the separation block, and athird opening 714 also located on the downstream end. A generallytubular section 716 of thehousing 701 forms thefirst opening 711 and generallytubular sections housing 701 form the second andthird openings - The
second opening 712 is generally aligned with thefirst opening 711 to form a first channel 715 (FIGS. 71 and 76 ). Thethird opening 714 leads to a second channel 717 (seeFIGS. 71 and 76 ) that joins with the first channel 715 at thetubular section 716 of thehousing 701.Tubular sections buffer tubes 222 andcentral strength member 226 of thedistribution cable 220.Tubular section 719 forming the second channel 717 is sized and shaped to fit within thetube 800 and to enclose thefibers 224 dc accessed from thedistribution cable 220 for splicing with thefibers 224 t of thetether cable 242. - In some embodiments, the
separation block 700 is formed from afirst section 710 and asecond section 750. In the example shown, the first andsecond sections grooves grooves section 720 a defines thegrooves section 720 b defines thegrooves - In some embodiments, the first and
second sections complementary surface depressions 722 and protrusions 724 (FIGS. 70 and 75 ). In one example embodiment, the protrudingsection 720 a on thefirst section 710 defines ahole 722 and the protrudingsection 720 b on thesecond section 750 includes aprotrusion 724 sized to fit within thehold 722. Adhesive can also be used to secure thefirst section 710 to thesecond section 750. - The mid-span breakout location on the
distribution cable 220 can be prepared in a similar manner to the preparation discussed above with respect toFIG. 52 . A portion of theouter jacket 230 of thedistribution cable 220 is first stripped away to provide a strippedregion 400′ (FIG. 53 ). One of thebuffer tubes 222 is selected and afirst window 408′ and a second window are cut into the selectedbuffer tube 222. Thefibers 224 dc desired to be broken out are then accessed, severed, and pulled from thebuffer tube 222 through thefirst window 408′. With thedistribution cable 220 prepared as shown inFIG. 80 , the severedfibers 224 dc are ready to be fused with thetether fibers 224 t. - To connect the
tether 242 to thefibers 224 dc, thesplice sleeve 246 and the tube 800 (FIG. 53 ) are first slid over thefibers 224 t of thetether 242, and thetube 800 is further slid up over thetether jacket 266. With thesplice sleeve 246 andtube 800 mounted on thetether 242, thefibers 224 t of the tether are fused to thefibers 224 dc of thedistribution cable 220. The fibers are then tested to confirm that the fibers meet minimum insertion loss requirements. - After the fusion process is complete, the
splice sleeve 246 can be slid over the fusion location to protect the splice. In some embodiments, thesplice sleeve 246 has a length of less than 40 mm. Preferably, thesplice sleeve 246 has a length of less than 35 mm. In one example embodiment, thesplice sleeve 246 has a length of about 30 mm. Decreasing the length of thesplice sleeve 246 increases the degree to which the mid-span breakout assembly can bend. Increasing the flexibility of thebreakout assembly distribution cable 220 having thebreakout assembly - After verifying the insertion loss, the
tube 800 can be slid over thesplice sleeve 246 and the fusion location to protect the splicedfibers separation block 700 can then be added to theupstream location 402′ of the strippedportion 400′ of thedistribution cable 220. Thebuffer tubes 222 are routed through the first channel 715 of theseparation block 700 and the severedfibers 224 dc are routed through the second channel 717 of the separation block 700 (FIG. 80 ). To route the fibers, in some embodiments, thebuffer tubes 222 are laid within thefirst groove 715 a of thefirst section 710 of theseparation block 700 and thefibers 224 dc are laid within thesecond groove 717 a of thefirst section 710 as shown inFIG. 79 . Thesecond section 750 of theseparation block 700 can be secured to the first section as discussed above. - Typically, the
separation block 700 does not enclose theouter strength member 228. In some embodiments, theouter strength member 228 can be redistributed uniformly about thebuffer tubes 222 of thedistribution cable 220 at the upstream and downstream ends 402′, 404′ after installing theseparation block 700. In such embodiments, theouter strength member 228 extends across thebreakout location 241′. - After installing the
separation block 700, thetube 800 can be slid ontosection 719 of theseparation block 700. In some embodiments, thetube 800 can optionally be taped or otherwise temporarily secured to theseparation block 700. In other embodiments, thetube 800 is permanently secured to theseparation block 700 with adhesive. In still other embodiments, thetube 800 is not secured to theseparation block 700. - The
retention block 600 is then mounted to thetether cable 242. Theretention block 600 is preferably positioned so that one end of thetube 800 is slid over thetransition flanges retention block 600 and the other end of thetube 800 remains oversection 719 of theseparation block 700. In general, thetube 800 has an appropriate length to provide thefibers mid-span access location 241′. Theretention block 600 is then affixed to thedistribution cable 220. In some embodiments, thegroove 630 of thebase 610 of the retention block is affixed (e.g., with adhesive) to theouter strength member 228 wrapped around thedistribution cable 220. - To finalize the assembly process, the heat resistant tape/foil can be wrapped around the
mid-span breakout location 241′. Thereafter, the process is completed by applying an overmold 260′ over themid-span breakout location 241′. The overmold layer 260′ functions to seal and protect the underlying components of themid-span breakout assembly 240′. Thereafter, thedistribution cable 220 can be spooled. It is preferred for thefibers 224 t of the tether to be pre-terminated to thefibers 224 dc of the distribution cable. The remainder of themid-span breakout assembly 240′ is also preferably factory installed. - As used herein, with respect to buffer tubes, the term “fiber access location” can be any type of location where a fiber can be routed out of a buffer tube. Example fiber access locations include windows, ring cut regions, or other openings in a buffer tube. Additionally, when the
fibers fibers - From the forgoing detailed description, it will be evident that modifications and variations can be made in the devices of the disclosure without departing from the spirit or scope of the invention.
Claims (20)
1. A telecommunications cable comprising:
a distribution cable including a cable jacket and at least a first buffer tube positioned within the cable jacket, the first buffer tube enclosing a first optical fiber, the distribution cable including a mid-span location where a portion of the cable jacket has been removed and where at least the first buffer tube includes a fiber access location through which the first optical fiber is routed out of the first buffer tube;
a tether that branches from the distribution cable at the mid-span location, the tether including a tether jacket, at least one strength member positioned within the jacket, a tether buffer tube positioned within the jacket, and a second optical fiber that extends through the tether buffer tube, the second optical fiber being spliced to the first optical fiber at a splice location; and
a tether retention block affixed to the distribution cable, the tether retention block including a first portion and a second portion that is configured to cooperate with the first portion to secure the tether buffer tube and at least the strength member of the tether, each of the first and second portions defining at least a first half-channel configured to cooperate with the first half-channel of the other portion to receive the strength member of the tether.
2. The telecommunications cable of claim 1 , wherein each of the first and second portions defines at least a second half-channel configured to cooperate with the second half-channel of the other portion to receive a second strength member of the tether.
3. The telecommunications cable of claim 1 , the tether retention block defines a passage through which the tether buffer tube extends, the passage being defined by the first and second portions.
4. The telecommunications cable of claim 1 , wherein the retention block defines a groove along which the distribution cable extends when the retention block is affixed to the distribution cable.
5. The telecommunications cable of claim 4 , wherein the first portion of the tether retention block defines the groove on a first side and defines the first half-channel on a second, opposite side.
6. The telecommunications cable of claim 1 , further comprising a flexible closure that surrounds the distribution cable and covers the mid-span location, the closure being factory installed, the closure being elongated along a length that extends along the distribution cable.
7. The telecommunications cable of claim 1 , further comprising:
a separation block coupled to the distribution cable at an opposite side of the mid-span location from the tether retention block, the separation block at least partially enclosing the first optical fiber;
a tube extending from the separation block to the tether retention block, wherein the second optical fiber splices to the first optical fiber within the tube.
8. The telecommunications cable of claim 7 , wherein each portion of the tether retention block includes a U-shaped flange configured to be inserted into one end of the tube.
9. The telecommunications cable of claim 1 , wherein at least a portion of the tether retention block is positioned within the closure.
10. The telecommunications cable of claim 1 , wherein the closure includes overmolding.
11. A method of securing a tether cable to a tether retention block having a cover and a base, the method comprising:
preparing the tether cable to expose a buffer tube and at least a first strength member;
positioning and securing the first strength member within a first side groove of the base;
positioning and securing the buffer tube within a central groove of the base; and
arranging the cover over the base including aligning a first side groove of the cover with the first side groove of the base to form a side passage through which the strength member at least partially extends and aligning a central groove of the cover with the central groove of the base to form a central passage through which the tether buffer tube at least partially extends.
12. The method of claim 11 , wherein preparing the tether cable to expose a buffer tube and at least a first strength member comprises:
stripping a portion of an outer jacket of a tether cable; and
removing an end portion of the buffer tube to expose the optical fiber within the buffer tube.
13. The method of claim 11 , wherein positioning the first strength member comprises positioning the first strength member having a length that is less than a length of the base; and wherein positioning the buffer tube comprises positioning the buffer tube having a length that is shorter than the length of the base and longer than the length of the first strength member.
14. The method of claim 11 , wherein arranging the cover over the base comprises:
aligning mating posts on one of the cover and the base with depressions provided on the other of the cover and the base; and
pressing the mating posts into the depressions.
15. The method of claim 14 , wherein aligning the mating posts with the depressions comprises aligning mating posts extending downwardly from the cover with depressions defined in a top of the base.
16. The method of claim 11 , further comprising applying an adhesive between the cover and the base to securely affix the tether cable to the retention block.
17. A tether retention block for securing a tether cable to a distribution cable, the tether retention block comprising:
a first portion having a first side and an opposite, second side, the first side of the first portion defining at least a first groove;
a second portion having a first side and an opposite, second side, the first side of the second portion defining at least a first groove configured to cooperate with the first groove of the first portion to define a passageway configured to receive a strength member and a tether buffer tube of the tether cable;
wherein the first portion defines a third groove configured to receive the distribution cable to secure the tether cable to the distribution cable, the groove being separate from the passageway.
18. The tether retention block of claim 17 , wherein the first groove of the second portion is configured to align with the first groove of the first portion to form a first tunnel in which the strength member of the tether cable is secured.
19. The tether retention block of claim 17 , wherein the second groove of the second portion is configured to align with the second groove of the first portion to form a second tunnel in which the tether buffer tube of the tether cable is secured.
20. The tether retention block of claim 17 , wherein the third groove is provided on the second side of the first portion.
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US12/612,182 Abandoned US20100080514A1 (en) | 2006-03-09 | 2009-11-04 | Fiber optic cable breakout configuration with retention block |
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US20100150504A1 (en) * | 2008-12-11 | 2010-06-17 | Tyco Electronics Corporation | Fiber optic multi dwelling unit deployment appartus and methods for using the same |
US8167504B2 (en) * | 2008-12-11 | 2012-05-01 | Tyco Electronics Corporation | Fiber optic multi dwelling unit deployment apparatus including a seamed protection jacket |
WO2012129207A1 (en) * | 2011-03-23 | 2012-09-27 | Afl Telecommunications Llc | Fiber optic cable |
GB2503161A (en) * | 2011-03-23 | 2013-12-18 | Afl Telecommunications Llc | Fiber optic cable |
WO2013063045A1 (en) * | 2011-10-26 | 2013-05-02 | Corning Cable Systems Llc | Composite cable breakout assembly |
US8842954B2 (en) | 2012-05-02 | 2014-09-23 | Corning Cable Systems Llc | Cable assembly |
US9285556B2 (en) | 2012-05-02 | 2016-03-15 | Corning Optical Communications LLC | Cable assembly |
WO2019190760A1 (en) * | 2018-03-29 | 2019-10-03 | Corning Research & Development Corporation | Pre-mold assembly for branched optical cable and related method |
US11256055B2 (en) | 2018-03-29 | 2022-02-22 | Corning Research & Development Corporation | Pre-mold assembly for branched optical cable and related method |
Also Published As
Publication number | Publication date |
---|---|
US7630606B2 (en) | 2009-12-08 |
WO2007103438A3 (en) | 2007-11-08 |
US7317863B2 (en) | 2008-01-08 |
WO2007103438A2 (en) | 2007-09-13 |
US20090022459A1 (en) | 2009-01-22 |
US20070212009A1 (en) | 2007-09-13 |
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