Functionally tensioned optical fibers to form ribbons with controlled geometry, optimized residual strain and reduced attenuation

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention generally relates to the field of optical fibers, in particular to the manufacture of fiber optic ribbons with functionally tensioned fibers to form ribbons with controlled geometrical configuration, optimized strain distribution and reduced attenuation. This invention introduces a new concept of “smart” ribbon which may have flat or bowed cross section and is straight along the length or curved in its plane, or twisted unidirectionally, or periodically. These shapes and residual stress-strain states are induced and controlled by using tension functions instead of traditional constant-value tension per fiber during the ribbon manufacture.

[0003] 2. Discussion of Related Art Optical fibers are very small diameter glass strands which are capable of transmitting an optical signal over great distances, at high speeds, and with relatively low signal loss as compared to standard wire or cable (including wire cable) networks. The use of optical fibers in today's technology has developed into many widespread areas, such as: medicine, aviation, communications, etc. Most applications of optical fibers require the individual fibers to be placed into groupings, such as in fiber optic cables.

[0004] There are many ways to manufacture and configure fiber optic cables. One of the most common forms is the use of fiber optic ribbons. A fiber optic ribbon is created when several individually insulated fibers are aligned side-by-side and then covered with a protective coating or matrix. This results in a flat fiber optic ribbon bundle (as opposed to a circular or round fiber optic tube bundle or loose wrapped bundle) which has the optical fibers held in positions parallel to each other in the same plane.

[0005] However, even though the use of the fiber optic ribbon is one of the most common ways optical fibers are employed in cables, and great advancements have been made in the use and methods of manufacturing ribbons, their manufacture is still not without problems. One of the most significant problems existing in current ribbons is the presence of residual twist in the ribbons after the ribbonizing process. Residual twist results in the manufactured ribbon not lying flat on flat surface or otherwise having geometric imperfections comprising the geometry of the ribbon. The presence of this residual twist has a number of adverse consequences, such as making it difficult to accurately align the individual fibers in a ribbon when two ribbons are being spliced. Fiber splicing is extremely sensitive to the geometrical imperfections existing in a ribbon, and imperfections that stem from residual twist make accurate splicing very difficult.

[0006] Another problem associated with residual twist is its adverse affect in the manufacture of fiber optic cables using ribbon stacks. Ribbon stacks are commonly made of a large number of individual fiber ribbons which are twisted together in a helical pattern for integrity of the ribbon stack. The presence of residual twist in the ribbons can create fiber attenuation when the residual twist of the individual ribbon is contrary to the twist patterns of the ribbon stack. This is particularly evident in the fibers which are positioned on the edges of the individual ribbons, which undergo large amounts of tension when twisted in a ribbon stack.

[0007] Another problem which exists in current ribbon manufacturing techniques is the uneven distribution of excess fiber length (EFL) in a ribbon. EFL is a ratio of individual fiber length compared to the actual length of the ribbon or cable length. It is generally desirable to have the individual fibers slightly longer than the cable or housing ribbon stack buffer tube or, in the case of an individual ribbon, the ribbon matrix material to prevent the individual fibers from tensile strain when the cable or ribbon itself is under a tensile load. It is highly desirable that the EFL ratio for each individual fiber in a ribbon have the same EFL, and close to zero residual strain to ensure minimum attenuation. However, under current manufacturing techniques it is found that the EFL distribution across an individual ribbon is uneven, where, for example, the edge fibers in a ribbon have a negative EFL because they have a residual tensile load, while the central fibers have a positive EFL because they have a residual compression load.

[0008] A further problem with current fibers, associated with above uneven EFL distributions, is the residual strains in the individual fibers after ribbon manufacture. These residual strains although by themselves may not cause a problem, when coupled with strains from the creation of a ribbon stack or through installation may cause additional tensile strain in the outer fibers while also causing additional compression strain in the central fibers. This can lead to signal loss and attenuation, delamination and buckling in the fibers and ribbons, all of which should be avoided.

[0009] Of course all of the above mentioned problems are magnified when not only are the ribbons curved or bent when placed in a cable, but when the cable itself is bent or curved during installation and handling.

[0010] It is believed that a large source for the above problems comes during the manufacturing phase of the ribbons, where different individual fibers being placed into a single ribbon undergo different forces and stresses caused by imbalances between the pulling and friction forces across a ribbon width, resulting in uneven stress and strain distributions across a single ribbon. Current ribbon manufacturing procedures use an equal tensile force (for example 80 grams) on each fiber being drawn into a ribbon. However, while the ribbon is being manufactured each of the fibers, in a ribbon, are undergoing different forces. These different forces result in the uneven stress and strain distributions, and the problems discussed above. One cause for the uneven stress distribution could be the location of the fibers. For example, the outer edge fibers (outermost two) have a higher contact area with the ribbon manufacturing equipment than the central fibers. This is depicted in FIG. 1, which shows twelve individual fibers 10 as they would appear in ribbon matrix material (not shown). This Figure clearly shows that the outermost ribbons have more surface contact area (contact on 3 sides) than central fibers (contact on only 2 sides) and thus would experience more drag or friction forces during manufacture, resulting in the creation of a residual tensile strain in the fibers. These friction forces are material, time and temperature dependant, and include variables such as the line speed of the ribbon manufacture process, the thickness of the ribbon matrix material, and the kinematic viscosity of the matrix material. Additionally, other factors such as ribbon material microstructure and thermal processing regime, including position and intensity of the heat source, also influence the difference in the friction forces on the edges and in the middle of the ribbon.

SUMMARY OF THE INVENTION

[0011] The present invention is directed to eliminating or greatly reducing the impact of the above problems by the use of non-uniform tensile loads on individual fibers during the ribbonizing process to adjust or alter the strain and EFL in the fibers and to create flat or geometrically stable curved ribbons with optimized strain distribution and reduced attenuation. This invention introduces a new concept of “smart” ribbon which may have flat or bowed cross section and is straight along the length or curved in its plane, or twisted unidirectionally, or periodically. These residual shapes and residual stress-strain states are induced and controlled by using tension functions instead of traditional constant-value tension per fiber during the ribbon manufacture. Also, these shapes and strain state are compliant with the subsequent ribbon configurations when the ribbons are stacked together, placed in a buffer tube and stranded around a central strength member or installed in the slots of a given geometry. The concept of the “smart” ribbon is based on the “round” strain functions:

ε(r,θ)=ε(r)

[0012] where ε is the normal strain along the fiber length, r is the distance from the geometrical center of the ribbon stack to the fiber, and Θ is the polar angle. According to the concept of this invention, the strain in the fiber should not change with the change in its angular position around the center of the stack. Also, it is often desirable to create a ribbon stack with close to

[0013] In the present invention, different tensile loads are applied to different fibers being placed in a single ribbon, during manufacture of the ribbon, to allow the geometric stability of the ribbon to be controlled or optimized. Different functional distributions of tensile forces can be used, including: (1) parabolic or sinusoidal distribution with a smaller tensile load being applied to the outermost fibers and a higher load being applied to the central fibers; (2) trapezoidal distribution of tension with a smaller tension on the outer most fibers and a higher constant-level tension on the central fibers; and (3) a hybrid parabolic-trapezoidal or sinusoidal-parabolic distribution having a rapid change in tensile force on the edge fibers as they progress in from the edge, with a shallow tensile load function for the central fibers. The present invention can be used to achieve both a flat ribbon, as desirable for splicing, or a fiber ribbon with a controlled non-flat shape or configuration depending on the application in which the ribbon is to be used. For example, ribbons can be produced where the outermost fibers have an increased EFL for better signal performance after being twisted, helically or otherwise stranded. The increased EFL will prevent the problems normally experienced in the outermost fibers due to high tensile strain when the whole ribbon stack is twisted.

[0014] Further, the present invention may also be used to create non-straight ribbons with in-plane controllable curvature. This is accomplished by using a non-symmetric tensile load function to define the tensile loads on the fibers across a ribbon being manufactured. The intentional and controlled creation of this residual curvature with a non-symmetric fiber load distribution can be efficiently used for creating controlled ribbon twist and stranding around a cable strength member in a curvilinear path (i.e. helical path), while avoiding the problems associated with the creation of high residual stresses and strains when the prior art methods of manufacture are used.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The advantages, nature and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments of the invention which are schematically set forth in the drawings, in which:

[0016]
FIG. 1 is a diagrammatical representation of a fiber optic ribbon without the matrix material, during ribbon manufacture showing representative forces experience during ribbon manufacture;

[0017]
FIG. 2A is a diagrammatical representation of a symmetric parabolic or sinusoidal strain distribution over a typical fiber optic ribbon as contemplated by the present invention;

[0018]
FIG. 2B is a diagrammatical representation of a symmetric trapezoidal strain distribution over a typical fiber optic ribbon as contemplated by the present invention;

[0019]
FIG. 2C is a diagrammatical representation of a symmetric hybrid parabolic-trapezoidal or sinusoidal-trapezoidal strain distribution over a typical fiber optic ribbon as contemplated by the present invention;

[0020]
FIG. 2D is a diagrammatical representation of a non-symmetric parabolic or sinusoidal strain distribution over a typical fiber optic ribbon as contemplated by the present invention;

[0021]
FIG. 2E is a diagrammatical representation of a non-symmetric trapezoidal strain distribution over a typical fiber optic ribbon as contemplated by the present invention; and

[0022]
FIG. 3 is a diagrammatical representation of a curvilinear stranded ribbon structure with reduced stress level using ribbons with in-plane curvature from non-symmetric fiber tensile forces during ribbon manufacture.

DETAILED DESCRIPTION OF THE INVENTION

[0023] The present invention will be explained in further detail by making reference to the accompanying drawings, which do not limit the scope of the invention in any way.

[0024] Turning now to FIGS. 2A through 2E, various tension functions for fiber stress during ribbon manufacture are shown. In FIG. 2A, a typical fiber optic ribbon 100 is shown along the X-axis of a graph, having a plurality (twelve) optical fibers 101. The Y-axis of the graph represents the tensile force applied to the individual optical fibers along the width of the fiber during manufacture. In this FIGURE, a symmetric parabolic or sinusoidal curve is shown where the tensile load on the end fibers is less than that on the center most fibers, while the fibers are being drawn. In the preferred embodiment of the present invention, the exact tensile load values and the function of the distribution over the fibers should be such as to result in a flat or otherwise geometrically stable ribbon after manufacture. Therefore, the exact loads and distribution to be used is to be tailored to the particular manufacturing process being used, because no one load distribution would be applicable for different manufacturing variations. Examples of factors to be taken into account when determining the proper load distribution are line speed of the ribbon manufacture process, the thickness of the ribbon matrix material, and the kinematic viscosity of the matrix material, as well as temperature, and time and location of curing stations. Although it is desirable to have a flat ribbon for geometric stability and the optimization of fiber spacing for splicing, it is contemplated that the parabolic or sinusoidal function can be modified or altered in any way to create a ribbon with the desired characteristics such as controlled residual twist or fiber strain.

[0025]
FIG. 2B is similar to FIG. 2A except that a symmetric trapezoidal load distribution is shown. Such a distribution may also result in a flat or otherwise geometrically stable fiber ribbon, depending on the load function used and the manufacturing parameters. However, unlike the distribution in FIG. 2A, this distribution applies an even load along the center most fibers (instead of varying the load with a peak load at the center). This distribution can be used as a cheaper, and easier to use, alternative to the parabolic or sinusoidal distribution previously discussed. This is because the central fibers all use the same load, thus simplifying the apparatus and method.

[0026]
FIG. 2C shows a hybrid symmetric load distribution which can be either a hybrid between parabolic and trapezoidal functions or between sinusoidal and trapezoidal functions. Again, in the preferred embodiment, the distribution across the ribbon would be symmetric and result in a flat and geometrically stable ribbon. However, as with the previous embodiments the load function can be altered or modified as required by the application of the ribbon to optimize or minimize ribbon strain and stress in the various intended ribbon applications.

[0027] It should be noted that although the figures above show the outermost fibers having lower loads than the central fibers, it is contemplated that the reverse can also be used. It may be desirable, in certain applications, to have higher EFL in the outermost fibers, thus during the manufacture of the ribbon a higher load may be used on the outermost fibers. This would be applicable when a higher EFL is needed for outer fibers in ribbons that are going to be wound or bent in the manufacture of a cable, or during any other installation. This is because during the bending or winding of ribbons, the outermost fibers undergo or experience the highest tensile loads (because they must stretch the furthest distance), therefore, an increased EFL in these fibers would allow the fibers to “give” as the ribbon in which they are in is stretched without increasing the strain (and subsequently attenuation) in the fibers.

[0028] Further, in addition to flat ribbons, it may be desirable to have a bowed ribbon, where either the center (or the ends) are desired to “bow” or bend. If this configuration is desirable, the above functions can be modified to create such a ribbon configuration. However, it should be further noted that the above functions are only intended for use on ribbons when it is desired that the ribbon be symmetrical.

[0029]
FIGS. 2D and 2E are directed to the creation of non-symmetrical ribbons. In particular, FIG. 2D shows a non-symmetrical parabolic or sinusoidal load function, where the left most fiber has a lower applied load then the right most fiber. This distribution would result in a clockwise in-plane residual turn and twist in the ribbon. Such a controlled curvature allows the manufacture of pre-twisted ribbons that can be used in cable application where the ribbons would normally be twisted or stranded as a stack of ribbons. The pre-twisting of the ribbons allows the ribbons to be placed into a twisted helical cable pattern (for example) without the outermost fibers experiencing the same tensile strain that would normally be experienced by a straight ribbon. If the ribbon is pre-shaped to follow the helical path it would follow when installed into a ribbon stack and placed in the slotted core or placed in the buffer tube subsequently stranded around a central strength member, then little or no strain is added to the fibers when the ribbon is in fact installed.

[0030] Another example of this non-symmetric loading of the fibers during the ribbonizing process is shown in FIG. 2E, which shows a non-symmetric trapezoidal loading configuration with more load being applied to the left most fiber than the right most fiber. This load distribution results in a counter-clockwise twist and in-plane bend in the completed ribbon.

[0031] It should be noted that the load distribution function used to define the loads for each fiber are to be determined by the ultimate application, and desired characteristics of the ribbon and individual fibers. The functions shown in FIGS. 2A through 2E are merely examples of functions that can be used, and the present invention contemplates and includes the use of many different functions, not shown, including but not limited to combinations of the above discussed functions. Further, it is noted that the present invention contemplates changing the applied load distribution on the fibers in a single ribbon during the ribbonizing process. Although most ribbon applications would require a finished ribbon with a constant geometry throughout its length, whether it be flat or bowed, or curved, in some applications it may be desirable to have the geometry of the ribbon change throughout the length of the ribbon.

[0032] This is accomplished by changing the load function over time during the manufacture of a single ribbon. For example, it may be desirable to have a ribbon which begins with a clockwise twist, but transitions to a counter-clockwise twist at some point along its length and back again. To accomplish this the function shown in FIG. 2D may be used when the ribbon manufacture starts, and then the load distribution transitions to a function directly opposite of that shown in FIG. 2D, and perhaps back again. An example of a ribbon manufactured in this process is shown in FIG. 3. This Figure shows a plurality of ribbons 300 twisted in an in-plane curvilinear path along a cable axis where the twist of the ribbons 300 reverses at points A. The twist reversal is accomplished by changing the fiber load distribution as previously discussed. It is noted that such an in-plane curvilinear path is a result of using a non-symmetric load distribution, examples of which are shown in FIGS. 2D and 2E.

[0033] The following Table I provides a qualitative characterization of fiber strain loads or distribution in fiber ribbons made with various methodology to demonstrate the advantages of the present invention, where “+” indicates the creation (or addition) of fiber tensile strain, “−” indicates the creation (or addition) of compressive strain on the individual fibers, and “0” indicates the creation (or addition) of no additional strain. (Note “SM” indicates strength member).

1STRAINS INTHE RIBBONSTRAINS AFTERSTRAINS AFTERMETHOD OFAFTERSTRAINS AFTERRIBBONCABLERIBBONRIBBONIZINGRIBBON STACKBENDINGBENDING ANDMANUF.PROCESSTWISTINGAROUND A SMTENSIONCOMMENTFlat Prior+ edge fibers+ edge fibers+ edge fibers++ edge fibersAs can be seen the edgeArt Ribbons− central fibers− central fibers0 central fibers+ central fibersfibers experience + strainObtainedat each stage of manuf.usingand installation, thusconstantultimately creatingtension persignificant strain andeach fibersignal attenuation in theedge fibers.Flat Ribbons0 edge fibers+ edge fibers+ edge fibers++ edge fibersIn this case the edgemade in0 central fibers− central fibers0 central fibers+ central fibersfibers experience lessaccordanceoverall strain because nowith theresidual strain exists frompresentthe ribbonizing process.invention.Flat Ribbons− edge fibers+ edge fibers+ edge fibers++ edge fibersHere because the edgewith+ central fibers− central fibers0 central fibers+ central fibersfibers begin with acompressedresidual compressionedge fibersstrain, which partiallyandcompensates for thetensionedtensile strain experiencedcentralin the application of thefibers.ribbon, the overall tensilestrain is reduced ascompared to the aboveexamples.Twisted+ left edge0 edge fibers0 edge fibers++ edge fibersAs can be seen thisRibbonsfiber0 central fibers0 central fibers+ central fibersconfiguration produceswith in-0 central fibersthe lowest stress gradientplane− right edgein the fibers, because ofcurvilinearfiberthe optimization of the in-shapes.plane curvature of theribbon prevents additionalstrain from being added tothe edge fibers duringstack twist and ribbonstranding in buffer tube orslotted core.

[0034] As can be seen from the above Table, the optimum load distribution function to be used for any one particular ribbon greatly depends on the ribbons ultimate use and installation requirements. As previously stated, the load distribution functions can be changed and optimized throughout the length of an individual ribbon (or could be different for different ribbons used in a same stack) to achieve the most desirable results.

[0035] Further, although in the preferred embodiment of the present invention, the loads applied to the fibers during ribbonizing are controlled by varying the draw tension in the fibers, the loads can also be controlled by any other commonly known or used way, such as altering the friction loads of the various fibers as they are being drawn through the ribbon die. Managing the friction loads as the fiber pass through the ribbon die can be accomplished by, for example, varying the characteristics of the ribbon matrix material across the ribbon structure or non-uniform thermal curing regime. Altered characteristics can include viscosity, molecular structure, temperature, thickness, etc.

[0036] It is of course understood that departures can be made from the preferred embodiments of the invention by those of ordinary skill in the art without departing from the spirit and scope of the invention that is limited only by the following claims.

Claims

1. A method for manufacturing a fiber optic ribbon, the method comprising: drawing a plurality of optical fibers through a fiber optic ribbon die wherein said plurality of fibers are in substantially the same plane; applying a first load to at least one of said fibers and at least a second load to at least one other of said fibers, wherein said first load is different from said second load; and applying a coating to said plurality of fibers.
2. The method as claimed in claim 1, wherein said first load is applied to each fiber on an end of said plurality of fibers and said second load is applied to at least one of said plurality of said fibers not on an end of said plurality of fibers.
3. The method as claimed in claim 1, wherein said first load is applied to a fiber on one end of said plurality of fibers and said second load is applied to a fiber on another end of said plurality of fibers.
4. The method as claimed in claim 1, further applying at least a third load to at least another of said plurality of fibers.
5. The method as claimed in claim 1, wherein at least one of said first and second loads varies during said drawing step.
6. The method as claimed in claim 1, wherein at least one of said first and said second loads is determined from at least one fiber load distribution function.
7. The method as claimed in claim 6, wherein said function is parabolic.
8. The method as claimed in claim 6, wherein said function is sinusoidal.
9. The method as claimed in claim 6, wherein said function is trapezoidal.
10. The method as claimed in claim 6, wherein said function is a combination of any two functions chosen from a group consisting of parabolic, sinusoidal and trapezoidal.
11. The method as claimed in claim 6, wherein said function provides a symmetric load distribution across said plurality of fibers.
12. The method as claimed in claim 6, wherein said function provides a non-symmetric load distribution across said plurality of fibers.
13. The method as claimed in claim 6, wherein said function changes during said drawing step.
14. The method as claimed in claim 1, wherein said first and second loads are applied such that said ribbon lies substantially flat on a substantially flat surface.
15. The method as claimed in claim 1, wherein said first and second loads are applied such that said ribbon twists along its length.
16. A fiber optic ribbon made by the method claimed in claim 1.
17. A fiber optic ribbon made by the method claimed in claim 6.
18. A method for manufacturing a fiber optic ribbon, the method comprising: drawing a plurality of optical fibers through a fiber optic ribbon die wherein said plurality of fibers are in substantially the same plane; applying a first load to at least one of said fibers located on an end of plurality of fibers and at least a second load to at least one other of said fibers, wherein said first load is different from said second load.
19. The method claimed in claim 18, wherein said second load is applied to another fiber located on an end of said plurality of fibers, and is either larger or smaller than said first load.
20. The method as claimed in claim 18, wherein said second load is applied to another fiber located adjacently to said end fiber and is either larger or smaller than said first load.
21. The method as claimed in claim 18, wherein said second load is applied on another fiber located centrally in said plurality of fiber and is either larger or smaller than said first load.
22. The method as claimed in claim 18, further applying at least a third load to at least another of said plurality of fibers.
23. The method as claimed in claim 18, wherein at least one of said first and second load varies during said drawing of said fibers.
24. The method as claimed in claim 18, wherein at least one of said first and said second loads is determined from at least one fiber load distribution function.
25. The method as claimed in claim 24, wherein said function is parabolic.
26. The method as claimed in claim 24, wherein said function is sinusoidal.
27. The method as claimed in claim 24, wherein said function is trapezoidal.
28. The method as claimed in claim 24, wherein said function is a combination of any two functions chosen from a group consisting of parabolic, sinusoidal and trapezoidal.

Functionally tensioned optical fibers to form ribbons with controlled geometry, optimized residual strain and reduced attenuation

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

US Classifications

International Classifications

Abstract

Description

Claims