OPTICAL FIBER AND ADHESIVE DISPENSER SYSTEM

Abstract

A system for installing an optical fiber cable in a building hallway or living unit includes an elongated cylinder for containing an adhesive, and a continuous length of an optical fiber cable embedded in the adhesive in a configuration that avoids kinks or knots in the cable. An elongated nozzle is fixed at a first end of the cylinder for depositing the adhesive and the cable from an open tip of the nozzle, along a desired routing path in the hallway or living unit. An applicator assembly is constructed and arranged for receiving the cylinder, and for applying a dispensing force at a second end of the cylinder opposite the first end so as to urge the adhesive and the cable out of the open tip of the nozzle.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to installations of optical fibers and cables inside private or commercial living units, and particularly to installations in which the fibers or cables are bonded to a supporting surface by an adhesive.

Discussion of the Known Art

Installations of optical cables inside a multi-dwelling unit or a single-family home require the cable to be hidden, or that the finished installation have little if any adverse visual impact on occupants in the unit or home. Hiding the cable, for example, above a ceiling, behind a wall, or inside a crown molding or baseboard, however, is not always an option. As used herein, the term cable is intended to mean one or more optical fibers whether or not buffered or jacketed.

A cable installation procedure developed by OFS Fitel, LLC and known by the mark InvisiLight®, allows an optical fiber cable to be installed along a wall of a building hallway without a need for a separate duct system to enclose and route the cable, or for metal clips to secure the cable to an underlying structure. Instead, an adhesive is used to bond the cable permanently to a wall, molding, or other supporting surface along the desired routing path. Because the adhesive dries white or clear, and the cable diameter is typically quite small, the finished installation is not likely to be noticed by persons nearby.

FIGS. 1A to 1F, and FIG. 2 illustrate the InvisiLight installation procedure. In FIGS. 1A to 1C, an installer deposits an adhesive bead 12 along a top edge of a baseboard molding 14 using an adhesive dispenser tool 16. FIGS. 1D to 1E show the installer setting an optical fiber cable 18, which is typically delivered to the installation site on a reel separately from the adhesive, into the deposited adhesive bead 12. In FIG. 2, an optical fiber cable 20 is set into an adhesive bead 22 that was previously deposited by an installer along an upper edge of a crown molding 24. In either case, once the adhesive bead 12, 22 dries and bonds the optical fiber cable 18, 20 in place, the cable blends into the edge of the baseboard molding 14 against the wall, or the edge of the crown molding 24 against the ceiling.

Accordingly, when using the procedure described above, the installation of a cable along a building hallway or inside of a living unit requires multiple steps, viz., the cable is pulled off of a supply spool or reel, and, in a separate process, the cable is urged into a previously deposited adhesive bead along a molding or other supporting surface. Alternatively, instead of using an adhesive, the cable may be secured along a wall or ceiling using metal or plastics clips. In either case, such a two-step process is time consuming and may result in inconsistent degrees of support for the cable over the desired routing path.

SUMMARY OF THE INVENTION

According to the invention, a system for installing an optical fiber cable in a building hallway or living unit includes an elongated cylinder or tube for containing an adhesive and a continuous length of an optical fiber cable embedded in the adhesive in a way that avoids formation of kinks or knots in the cable. An elongated nozzle is configured to be fixed at a first end of the cylinder to deposit the adhesive and the cable from an open tip of the nozzle along a desired routing .path in the hallway or living unit. An applicator assembly receives the cylinder and applies a dispensing force at a second end of the cylinder opposite the first end, thus urging both the adhesive and the cable simultaneously out of the open tip of the nozzle.

For a better understanding of the invention, reference is made to the following description taken in conjunction with the accompanying drawing and the appended claims.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

In the drawing:

FIGS. 1A to 1C show an application of an adhesive bead along a top edge of a baseboard molding;

FIGS. 1D to 1F show an optical fiber cable being set into the adhesive bead;

FIG. 2 shows an optical fiber cable set into an adhesive bead previously applied along an upper edge of a crown molding;

FIG. 3 shows a system for depositing an adhesive bead along a supporting surface while simultaneously setting an optical fiber or cable into the bead, according to the invention.

FIG. 4 is a schematic representation of the contents of a dispensing tube or cylinder in the system in FIG. 3, according to the invention;

FIG. 5 is a top view looking into the dispensing tube in FIG. 3;

FIG. 6 is an isometric side view of the dispensing tube in FIG. 3, including a dispensing tip or nozzle according to the invention;

FIG. 7 is an isometric view of a cap for the nozzle in FIG. 6, and

FIG. 8 is a view of the open end of the nozzle in FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 3 shows a system 50 for depositing an adhesive bead along a wall, ceiling, molding, or other supporting surface while simultaneously embedding an optical fiber or cable in the bead, according to the invention.

In the illustrated embodiment, an applicator 52 in the form of, for example, a conventional chalking tool or gun, is constructed and arranged to receive a dispenser cylinder 54 that contains both the adhesive and a continuous length of an optical fiber cable 56 embedded within the adhesive, A non-standard shape for the applicator 52 can be used with the same functionality; however, a customized tool would then be required.

The cable 56 is wound in either a layered figure eight configuration as in FIG. 4, or a circular helical configuration, to avoid kinking or knotting up while the cable 56 is being dispensed. That is, both the cable 56 and the adhesive are loaded within the cylinder 54 in such a way that the cable and the adhesive are dispensed simultaneously. As the cable 56 is guided along a wall or molding, the adhesive surrounding the cable will bond the cable to the wall or molding without a need for a second application step once the adhesive cures.

A nozzle 60 is fixed to a top end of the cylinder 54. As seen in FIG. 8, the nozzle 60 is split or divided into two separate passageways 60a, 60b to receive and manage dispensing of the adhesive and the cable 56 simultaneously. An angled cut can be formed at the end of the nozzle 60 to control the speed of adhesive dispensing and to keep the cable encapsulated within the adhesive. Moreover, a mark may be placed on the nozzle to inform the installer of the proper direction of applicator movement during installation that will ensure the cable is completely encapsulated by the adhesive.

As mentioned, the cable 56 must be held inside the cylinder 54 in such a way that the cable can be dispensed (i.e., pushed or pulled out) without knotting or breaking. This can be achieved by one of several ways:

1. By placing the cable freely in a figure eight pattern within the cylinder 54 which allows for dispensing continuously without forming kinks or knots in the cable;

2. Placing the cable in a circular coil or helical form; or

3. Placing the cable on a circular spool that fits within the cylinder 54 and which keeps the cable from knotting.

A threaded sealed cap 64, shown in FIG. 7, may be used to keep adhesive remaining inside the cylinder 54 from drying prior to and after installation. The cap 64 is cylindrical in shape to allow for a leading end section of cable 56 to be kept accessible. Thus, when the cap 64 is removed, the cable can be accessed easily to start application against a surface.

Examples of fiber cable outside diameter (O.D.) dimensions:

One (1) fiber cables: Bare fibers or coated fibers of 250, 500, 600, or 900 urn O.D. buffered fiber.

Two to 24 fiber cables: 1.2 mm, 2 mm, and 3 mm O.D. jacketed cables.

Rollable Ribbon Structures.

It will be appreciated that the present invention allows for the dispensing of an optical fiber cable and a securing adhesive in one continuous process. A faster and more consistent installation is therefore obtained when compared to the prior known processes.

The invention can be practiced in cases where the fiber cable 56 must pass through holes drilled in a wall or other structure during the installation process. In a typical installation, the cable must pass through at least one hole and often two or three holes. The holes may be located at any point of the fiber routing path.

Note that a tube or cylinder 54 having a 8 mm inner diameter (ID) and a 10 mm outer diameter (OD) could be pushed through holes along the installation path to enable the cable 56 to be threaded through the holes. For example, without limitation, an 8 mm ID/10 mm OD tube 300 mm in length containing a 0.6 mm, 0.25 mm, or 0.20 mm OD fiber cable would hold approximately 12.4 meters, 30 meters, or 37.7 meters of the cable, respectively.

While the foregoing describes and illustrates preferred embodiments of the present invention, it will be understood by persons of ordinary skill in the art that various changes, modifications, and additions can be made without departing from the spirit and scope of the invention,

For example, the present invention is not limited only to cable installations inside of a building. Moreover, the adhesive material may contain UV protection, and have color as well as fire protection qualities.

Further, if the cable is an optical fiber or a buffered optical fiber having a textured outer surface, friction between the adhesive when wet and the outer surface of the fiber can be increased to facilitate co-extrusion of the fiber. The textured outer surface will also increase the volume of adhesive captured and retained by the fiber as it exits the nozzle opening. In addition, the fiber may be pre-terminated with an optical connector on one or both ends of the fiber, wherein the connector is situated outside of the nozzle 60 and the tube or cylinder 54.

Accordingly, the invention includes all such changes, modifications, and additions that are within the scope of the following claims.

Claims

1. A system for installing an optical fiber cable in a building hallway or living unit, comprising: an elongated cylinder or tube for containing an adhesive and a continuous length of an optical fiber or cable embedded in the adhesive in a configuration that avoids formation of kinks or knots in the cable;an elongated nozzle configured to be fixed at a first end of the cylinder for depositing the adhesive and the cable from an open tip of the nozzle along a desired routing .path in the building hallway or living unit; andan applicator assembly constructed and arranged for receiving the cylinder and for applying a dispensing force at a second end of the cylinder opposite the first end to urge the adhesive and the cable out of the open tip of the nozzle.

2. A system according to claim 1, wherein the optical fiber cable is embedded in the adhesive contained in the cylinder in a circular helical form.

3. A system according to claim 1, wherein the optical fiber cable is embedded in the adhesive contained in the cylinder in a continuous layered figure eight form.

4. A system according to claim 1, wherein the nozzle has a first passageway for receiving the adhesive contained in the cylinder, and a second passageway for receiving the optical fiber cable separately from the adhesive in which the cable is embedded inside the cylinder.

5. A system according to claim 4, wherein the tip of the nozzle is configured for depositing the adhesive in the first passageway and the optical fiber cable in the second passageway so that the cable is set within the deposited adhesive along the desired routing path in response to operation of the applicator.

6. A system according to claim 1, wherein the applicator is in the form of a chalking tool or gun.

7. A system according to claim 1, wherein the elongated cylinder or tube has an outer diameter of less than 1 inch (25.4 mm).

8. A system according to claim 1, wherein the cable is an optical fiber or a buffered optical fiber having a textured outer surface so that friction between the adhesive when wet and the outer surface of the fiber is increased to facilitate co-extrusion of the fiber.

9. A system according to claim 1, wherein the cable is an optical fiber or a buffered optical fiber having a textured outer surface for increasing the volume of adhesive captured and retained by the fiber as it exits the nozzle opening.

10. A system according to claim 1, wherein the cable is an optical fiber or a buffered optical fiber, and including an optical fiber connector pre-terminated on one or both ends of the fiber, wherein the connector is situated outside of the nozzle, the tube, or the cylinder.