USRE50314E1 - Fiber optic cable assembly and method - Google Patents

Abstract

A fiber optic cable assembly includes an outer jacket defining a first passage and a second passage disposed adjacent to the first passage. The outer jacket includes a wall disposed between an outer surface of the outer jacket and the first passage. A plurality of optical fibers is disposed in the first passage. A reinforcing member is disposed in the second passage. An access member is disposed in the wall of the outer jacket.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The current application is an application for reissue of U.S. Pat. No. 8,363,994B2, dated Jan. 29, 2013, which issued from U.S. patent application Ser. No. 13/038,996, filed Mar. 2, 2011, and which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/394,218, filed Oct. 18, 2010 and also claims the benefit of U.S. Provisional Patent Application Ser. No. 61/309,676, filed Mar. 2, 2010, which applications are hereby incorporated by reference in their entireties.

BACKGROUND

A fiber optic cable typically includes: (1) an optical fiber; (2) a buffer layer that surrounds the optical fiber; (3) a plurality of reinforcing members loosely surrounding the buffer layer; and (4) an outer jacket. Optical fibers function to carry optical signals. A typical optical fiber includes an inner core surrounded by a cladding that is protected by a coating. The buffer layer functions to surround and protect the coated optical fibers. Reinforcing members add mechanical reinforcement to fiber optic cables to protect the internal optical fibers against stresses applied to the cables during installation and thereafter. Outer jackets also provide protection against chemical damage.

Drop cables used in fiber optic networks can be constructed having a jacket with a flat transverse profile. Such cables typically include a central buffer tube containing a plurality of optical fibers, and reinforcing members such as rods made of glass reinforced epoxy embedded in the jacket on opposite sides of the buffer tube. U.S. Pat. No. 6,542,674 discloses a drop cable of a type described above. Flat drop cables of the type described above are designed to be quite robust. However, as a result of such cables being strong and robust, such cables are typically quite stiff, inflexible and difficult to handle. Additionally, such cables can be expensive to manufacture.

SUMMARY

An aspect of the present disclosure relates to a fiber optic cable. The fiber optic cable includes an outer jacket defining a first passage and a second passage disposed adjacent to the first passage. The outer jacket includes a wall disposed between an outer surface of the outer jacket and the first passage. A plurality of optical fibers is disposed in the first passage. A reinforcing member is disposed in the second passage. An access member is disposed in the wall of the outer jacket.

Another aspect of the present disclosure relates to a fiber optic cable assembly. The fiber optic cable assembly includes an outer jacket defining a first passage and a second passage. The second passage is disposed adjacent to the first passage. The outer jacket includes a major axis that extends through a center of the outer jacket and a minor axis that extends through the center. The minor axis is generally perpendicular to the major axis. The outer jacket includes a first wall disposed between an outer surface of the outer jacket and the first passage and a second wall disposed between the outer surface of the outer jacket and the first passage. The first and second walls are disposed on opposite sides of the major axis. A plurality of optical fibers is disposed in the first passage. A reinforcing member is disposed in the second passage. A first access member is disposed in the first wall of the outer jacket. A second access member is disposed in the second wall of the outer jacket.

Another aspect of the present disclosure relates to a fiber optic cable assembly. The fiber optic cable assembly includes an outer jacket that defines a first passage and a second passage disposed adjacent to the first passage. The outer jacket includes a major axis that extends through a center of the outer jacket and a minor axis that extends through the center. The minor axis is generally perpendicular to the major axis. The outer jacket includes a wall disposed between an outer surface of the outer jacket and the first passage. A plurality of optical fibers is disposed in the first passage. A reinforcing member is disposed in the second passage. A first access member is disposed in the wall of the outer jacket. A second access member is disposed in the wall of the outer jacket. The first and second access members are disposed on the same side of the outer jacket as divided by the major axis.

Another aspect of the present disclosure relates to a method for accessing the optical fibers of the fiber optic cable assembly. The method includes applying a force to a portion of an outer jacket of a fiber optic cable assembly. The force is applied in a direction that is outward from a lengthwise axis of the fiber optic cable assembly. The force is of a magnitude that causes each of a first portion of a wall of the outer jacket disposed between an outer surface of the outer jacket and an access member and a second portion of the wall disposed between the access member and a first passage defined by the outer jacket to tear. The portion of the outer jacket is pulled until a desired length of the portion is separated from a remaining portion of the outer jacket. The optical fibers in the first passage of the outer jacket are accessed.

Another aspect of the present disclosure relates to a method for accessing the optical fibers of the fiber optic cable assembly. The method includes providing a fiber optic cable assembly having an outer jacket defining a passage. The passage contains an optical fiber. The outer jacket includes a wall having a first portion that extends from the passage to an access member and a second portion that extends from the access member to an outer surface of the outer jacket. The outer jacket is tensioned adjacent to the access member to tear the first and second portions without pulling on the access member.

A variety of additional aspects will be set forth in the description that follows. These aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which the embodiments disclosed herein are based.

DRAWINGS

FIG.1 is a front view of a fiber optic cable having exemplary features of aspects in accordance with the principles of the present disclosure.

FIG.2 is a cross-sectional view of the fiber optic cable taken on line2-2 ofFIG.1.

FIG.3 is a perspective view of an optical fiber suitable for use with the fiber optic cable ofFIG.1.

FIG.4 is a perspective view of a fiber bundle suitable for use with the fiber optic cable ofFIG.1.

FIG.5 is a fragmentary view of an outer jacket of the fiber optic cable ofFIG.1.

FIG.6 is a cross-sectional view of the fiber optic cable showing a portion of the fiber optic cable separated from a remaining portion.

FIG.7 is a side view of the fiber optic cable ofFIG.6.

FIG.8 is a cross-sectional view of an alternate embodiment of a fiber optic cable.

FIG.9 is a cross-sectional view of the fiber optic cable ofFIG.8 with a portion of the fiber optic cable separated from a remaining portion.

DETAILED DESCRIPTION

Reference will now be made in detail to the exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structure.

Referring now toFIGS.1 and2, a fiberoptic cable assembly10 is shown. The fiberoptic cable assembly10 includes at least oneoptical fiber12 and a reinforcingmember14. The fiberoptic cable assembly10 further includes anouter jacket16 that surrounds theoptical fiber12 and thestrength member14.

In the depicted embodiment, the fiberoptic cable assembly10 includes a plurality ofoptical fibers12. In one embodiment, the fiberoptic cable assembly10 includes twelveoptical fibers12. In another embodiment, the fiberoptic cable assembly10 includes 48, 72, or 144optical fibers12.

Referring now toFIG.3, theoptical fiber12 is shown. Theoptical fiber12 can have any number of configurations. In the depicted embodiment ofFIG.3, theoptical fiber12 includes acore20. Thecore20 is made of a glass material, such as a silica-based material, having an index of refraction. In the subject embodiment, thecore20 has an outer diameter D₁of less than or equal to about 10 μm.

Thecore20 of eachoptical fiber12 is surrounded by afirst cladding layer22 that is also made of a glass material, such as a silica based-material. Thefirst cladding layer22 has an index of refraction that is less than the index of refraction of thecore20. This difference between the index of refraction of thefirst cladding layer22 and the index of refraction of thecore20 allows an optical signal that is transmitted through theoptical fiber12 to be confined to thecore20.

Asecond cladding layer24 surrounds thefirst cladding layer22. Thesecond cladding layer24 has an index of refraction. In the subject embodiment, the index of refraction of thesecond cladding layer24 is about equal to the index of refraction of thefirst cladding layer22. Thesecond cladding layer24 is immediately adjacent to thefirst cladding layer22. In the subject embodiment, thesecond cladding layer24 has an outer diameter D₂of less than or equal to 125 μm.

A coating, generally designated26, surrounds thesecond cladding layer24. Thecoating26 includes aninner layer28 and anouter layer30. In the subject embodiment, theinner layer28 of thecoating26 is immediately adjacent to thesecond cladding layer24 such that theinner layer28 surrounds thesecond cladding layer24. Theinner layer28 is a polymeric material (e.g., polyvinyl chloride, polyethylenes, polyurethanes, polypropylenes, polyvinylidene fluorides, ethylene vinyl acetate, nylon, polyester, or other materials) having a low modulus of elasticity. The low modulus of elasticity of theinner layer28 functions to protect theoptical fiber12 from microbending.

Theouter layer30 of thecoating26 is a polymeric material having a higher modulus of elasticity than theinner layer28. In the subject embodiment, theouter layer30 of thecoating26 is immediately adjacent to theinner layer28 such that theouter layer30 surrounds theinner layer28. The higher modulus of elasticity of theouter layer30 functions to mechanically protect and retain the shape ofoptical fiber12 during handling. In the subject embodiment, theouter layer30 defines an outer diameter D₃of less than or equal to 300 μm. In another embodiment, the outer diameter D₃of theouter layer30 is less than or equal to 250 μm. In another embodiment, the outer diameter D₃of theouter layer30 is less than or equal to 200 μm.

In the subject embodiment, theoptical fiber12 is manufactured to reduce the sensitivity of theoptical fiber12 to micro or macro-bending (hereinafter referred to as “bend-insensitive”). An exemplary bend insensitive optical fiber has been described in U.S. Pat. Nos. 7,587,111 and 7,623,747 that are hereby incorporated by reference in their entirety. An exemplary bend-insensitive optical fiber is commercially available from Draka Comteq under the name BendBright XS.

Referring now toFIG.4, a fiber bundle32 ofoptical fibers12 is shown. While theoptical fibers12 can be loosely disposed in the fiberoptic cable assembly10, the plurality ofoptical fibers12 can be bundled to form the fiber bundle32. In the depicted embodiment ofFIG.4, theoptical fibers12 are contra-helically served.

The fiber bundle32 includesfiber grouping members34. Thefiber grouping members34 are adapted to group theoptical fibers12 in the fiber bundle32. In the subject embodiment, thefiber grouping members34 include a first fiber grouping member34a and a second fiber grouping member34b. The first and second fiber grouping members34a,34b are arranged immediately about the plurality ofoptical fibers12 in a generally reverse double helical configuration along the length of theoptical fibers12. With the first and second fiber grouping members34a,34b disposed immediately about the plurality ofoptical fibers12, there is no intermediate layer disposed between the first and second fiber grouping members34a,34b and the plurality ofoptical fibers12.

In the reverse double helical configuration, the first fiber grouping member34a spirals about the length of theoptical fibers12 in a first direction while the second fiber grouping member34b spirals about the length of theoptical fibers12 in a second direction, which is opposite from the first direction. In the subject embodiment, the first direction is a clockwise direction and the second direction is a counterclockwise direction. This reverse double helical arrangement of the first and second fiber grouping members34a,34b about the plurality ofoptical fibers12 groups and retains the plurality of optical fibers in the fiber bundle32.

Referring now toFIG.2, the reinforcingmember14 will be described. The reinforcingmember14 of the fiberoptic cable assembly10 is adapted to resist axial forces applied to the fiberoptic cable assembly10.

The reinforcingmember14 preferably has a transverse cross-sectional profile that is generally rectangular in shape. As shown atFIG.2, the reinforcingmember14 has a transverse cross-sectional width W1 that is greater than a transverse cross-sectional thickness T1 of the reinforcingmember14. In certain embodiments, the width W1 of the reinforcingmember14 is at least 50% longer than the thickness T1, or the width W1 of the reinforcingmember14 is at least 75% longer than the thickness T1, or the width W1 of the reinforcingmember14 is at least 100% longer than the thickness T1, or the width W1 of the reinforcingmember14 is at least 200% longer than the thickness T1, or the width W1 of the reinforcingmember14 is at least 300% longer than the thickness T1, or the width W1 of the reinforcingmember14 is at least 400% longer than the thickness T1. As depicted inFIG.2, the width W1 is a maximum width of the reinforcingmember14 and the thickness T1 is a maximum thickness of the reinforcingmember14.

The reinforcingmember14 preferably has a construction that is highly flexible and highly strong in tension. For example, in certain embodiments, the reinforcingmember14 provides the vast majority of the tensile load capacity of the fiberoptic cable assembly10. For example, in one embodiment, the reinforcingmember14 carries at least 95% of a 150 pound tensile load applied to the fiberoptic cable assembly10 in a direction along alengthwise axis35. In one embodiment, the reinforcingmember14 can carry a 150 pound tensile load applied in an orientation extending along a central longitudinal axis of the reinforcingmember14 without undergoing meaningful deterioration of the tensile properties of the reinforcingmember14. In another embodiment, the reinforcingmember14 can carry a 200 pound tensile load applied in an orientation extending along the central longitudinal axis of the reinforcingmember14 without undergoing meaningful deterioration in its tensile properties. In still another embodiment, the reinforcingmember14 can carry a 300 pound tensile load applied in an orientation that extends along the central longitudinal axis of the reinforcingmember14 without experiencing meaningful deterioration of its tensile properties.

In certain embodiments, the reinforcingmember14 is formed by a generally flat layer of reinforcing elements (e.g., fibers or yarns such as aramid fibers or yarns) embedded or otherwise integrated within a binder to form a flat reinforcing structure (e.g., a structure such as a sheet-like structure, a film-like structure, or a tape-like structure). In one example embodiment, the binder is a polymeric material such ethylene acetate acrylite (e.g., UV-cured, etc.), silicon (e.g., RTV, etc.), polyester films (e.g., biaxially oriented polyethylene terephthalate polyester film, etc.), and polyisobutylene. In other example instances, the binder may be a matrix material, an adhesive material, a finish material, or another type of material that binds, couples or otherwise mechanically links together reinforcing elements.

In other embodiments, the reinforcingmember14 can have a glass reinforced polymer (GRP) construction. The glass reinforced polymer can include a polymer base material reinforced by a plurality of glass fibers such as E-glass, S-glass or other types of glass fiber. The polymer used in the glass reinforced polymer is preferably relatively soft and flexible after curing. For example, in one embodiment, the polymer has a Shore A hardness less than50 after curing. In other embodiments, the polymer has a Shore A hardness less than46 after curing. In certain other embodiments, the polymer has a Shore A hardness in the range of about 34-46.

In one embodiment, the reinforcingmember14 can have a width of about 0.085 inches and a thickness of about 0.045 inches. In another embodiment, such a reinforcingmember14 may have a width of about 0.125 inches and a thickness of about 0.030 inches. In still further embodiments, the reinforcingmember14 has a thickness in the range of 0.020-0.040 inches, or in the range of 0.010-0.040 inches, or in the range of 0.025-0.035 inches. Of course, other dimensions could be used as well. In additional embodiments, the reinforcingmember14 may have a width in the range of 0.070-0.150 inches. Of course, other sizes could be used as well.

In certain embodiments, the reinforcingmember14 preferably does not provide the fiberoptic cable assembly10 with meaningful resistance to compression loading in an orientation extending along thelengthwise axis35. For example, in certain embodiments, theouter jacket16 provides greater resistance to compression than the reinforcingmember14 in an orientation extending along thelengthwise axis35.

Referring now toFIGS.1 and2, theouter jacket16 of the fiberoptic cable assembly10 will be described. In the depicted embodiment, theouter jacket16 has a non-circular outer profile. For example, as shown atFIG.2, when viewed in transverse cross-section, the outer profile of theouter jacket16 has a flat generally obround or rectangular shape. Theouter jacket16 includes a major axis36 and aminor axis38. The major andminor axes36,38 are perpendicular to one another and intersect at acenter40 of theouter jacket16. A width W2 of theouter jacket16 extends along the major axis36 and a thickness T2 of theouter jacket16 extends along theminor axis38. The width W2 is longer than the thickness T2. In certain embodiments, the width W2 is at least 50% longer than the thickness T2. As depicted inFIG.1, the width W2 is a maximum width of theouter jacket16 and the thickness T2 is a maximum thickness of theouter jacket16.

Theouter jacket16 includes a base material that is a thermoplastic material. In one embodiment, the base material is a low-smoke zero halogen material such as low-smoke zero halogen polyolefin and polycarbonate. In another embodiment, the base material of theouter jacket16 is a conventional thermoplastic material such as polyethylene, polypropylene, ethylene-propylene, copolymers, polystyrene and styrene copolymers, polyvinyl chloride, polyamide (nylon), polyesters such as polyethylene terephthalate, polyetheretherketone, polyphenylene sulfide, polyetherimide, polybutylene terephthalate, as well as other thermoplastic materials.

In one embodiment, theouter jacket16 includes a plurality of shrinkage reduction material disposed in the base material. The shrinkage reduction material in the base material of theouter jacket16 is adapted to resist post-extrusion shrinkage. U.S. Pat. No. 7,379,642 describes an exemplary use of shrinkage reduction material in the base material of the outer jacket and is hereby incorporated by reference in its entirety.

In one embodiment, the shrinkage reduction material is liquid crystal polymer (LCP). Examples of liquid crystal polymers suitable for use in themulti-fiber cable assembly10 are described in U.S. Pat. Nos. 3,991,014; 4,067,852; 4,083,829; 4,130,545; 4,161,470; 4,318,842; and 4,468,364 and are hereby incorporated by reference in their entireties.

In order to promote flexibility in the fiberoptic cable assembly10, the concentration of shrinkage reduction material is relatively small as compared to the base material. In one embodiment, and by way of example only, the shrinkage reduction material constitutes less than about 10% of the total weight of theouter jacket16. In another embodiment, and by way of example only, the shrinkage reduction material constitutes less than about 5% of the total weight of theouter jacket16. In another embodiment, the shrinkage reduction material constitutes less than about 2% of the total weight of theouter jacket16. In another embodiment, the shrinkage reduction material constitutes less than about 1.9%, less than about 1.8%, less than about 1.7%, less than about 1.6%, less than about 1.5%, less than about 1.4%, less than about 1.3%, less than about 1.2%, less than about 1.1%, or less than about 1% of the total weight of theouter jacket16.

Theouter jacket16 defines afirst passage42 and a second passage44. In the depicted embodiment ofFIG.2, thefirst passage42 has a generally circular profile. Thefirst passage42 defines a center that is offset from thecenter40 of theouter jacket16.

Thefirst passage42 is adapted to receive the plurality ofoptical fibers12. The plurality ofoptical fibers12 is disposed directly in thefirst passage42 so that there is no intermediate layer (e.g., buffer tube, strength layer, etc.) disposed between the plurality ofoptical fibers12 and theouter jacket16. Thefirst passage42 extends the length of the fiberoptic cable assembly10.

The second passage44 is adapted to receive the reinforcingmember14. In the depicted embodiment, the second passage44 has a non-circular profile. For example, as shown atFIG.1, when viewed in transverse cross-section, the second passage44 has a generally obround or rectangular shape.

In one embodiment, the reinforcingmember14 is bonded to the second passage44 of theouter jacket16. The bonding between the reinforcingmember14 and theouter jacket16 can be chemical bonding or thermal bonding. In one embodiment, the reinforcingmember14 may be coated with or otherwise provided with a material having bonding characteristics (e.g., ethylene acetate) to bond the reinforcingmember14 to theouter jacket16.

The second passage44 is disposed adjacent to thefirst passage42. In the depicted embodiment, the second passage44 is offset from thecenter40 of theouter jacket16. The second passage44 is disposed in theouter jacket16 so that the width W1 of the reinforcingmember14 is disposed along the major axis36 of theouter jacket16.

Referring now toFIGS.2 and5, the fiberoptic cable assembly10 includes a wall46 disposed between anouter surface48 of theouter jacket16 and an inner diameter of thefirst passage42. Theouter jacket16 forms the wall46. The wall46 includes a thickness T3. In the depicted embodiment, theouter surface48 of the wall46 is continuous. It will be understood that the term “continuous” means that there are no indentations or lines of weakness in theouter surface48 of theouter jacket16.

The fiberoptic cable assembly10 further includes at least oneaccess member50 disposed in the wall46 of theouter jacket16. In one embodiment, theaccess member50 is a monofilament having a generally circular cross-section. In one embodiment, theaccess member50 is made of a material having a melting point temperature that is greater than the melting point temperature of the material of theouter jacket16.

Theaccess member50 includes an outer diameter D. In one embodiment, the outer diameter D of theaccess member50 is at least 30% of the thickness T3 of the wall46. In another embodiment, the outer diameter D of theaccess member50 is at least 40% of the thickness T3 of the wall46.

Theouter jacket16 defines an access member passage52 that extends the length of the fiberoptic cable assembly10. The access member passage52 of theouter jacket16 has an inner diameter that is generally equal to the outer diameter D of theaccess member50.

Referring now toFIG.5, theouter jacket16 includes afirst portion54 of the wall46 and a second portion56. Thefirst portion54 of the wall46 extends between theouter surface48 of theouter jacket16 and the inner diameter of the access member passage52. Thefirst portion54 of the wall46 has a thickness T4.

The second portion56 of the wall46 extends between the inner diameter of thefirst passage42 and the inner diameter of the access member passage52. The second portion56 of the wall46 has a thickness T5. In the depicted embodiment, the second portion56 of the wall46 is oppositely disposed from thefirst portion54 of the wall46.

The thickness T4 of thefirst portion54, the thickness T5 of the second portion56 and the outer diameter D of theaccess member50 cooperatively make up the thickness T3 of the wall46. In the depicted embodiment, the thickness T4 of thefirst portion54 is generally equal to the thickness T5 of the second portion56. In one embodiment, the thickness T4 of thefirst portion54 is at most 0.010 inches. In another embodiment, the thickness T4 of thefirst portion54 of the wall46 is at most 0.0075 inches. In another embodiment, the thickness T4 of thefirst portion54 of the wall46 is at most 0.005 inches. In one embodiment, the thickness T5 of the second portion56 is at most 0.010 inches. In another embodiment, the thickness T5 of the second portion56 of the wall46 is at most 0.0075 inches. In another embodiment, the thickness T5 of the second portion56 of the wall46 is at most 0.005 inches. In the depicted embodiment, the thickness T4 of thefirst portion54 is generally equal to the thickness T5 of the second portion56.

In the depicted embodiment ofFIG.2, the fiberoptic cable assembly10 includes a first access member50a and a second access member50b. The first and second access members50a,50b are disposed on opposite sides of thefirst passage42 so that each of the first and second access members50a,50b are disposed on an axis58 that extends through a center of thefirst passage42 where the axis58 is generally perpendicular to the major axis36 of the fiberoptic cable assembly10. In the depicted embodiment, the first and second access members50a,50b are disposed on opposite sides of the fiberoptic cable assembly10 as divided by the major axis36 but on the same side of the fiberoptic cable assembly10 as divided by theminor axis38.

Referring now toFIGS.5,6 and7, a method for accessing theoptical fibers12 of the fiberoptic cable assembly10 will be described. A force F is applied to a portion60 of theouter jacket16. The portion60 extends between the first and second access members50a,50b. In the subject embodiment, the portion60 is on the opposite side of theminor axis38 of the fiberoptic cable assembly10 from the reinforcingmember14. In the depicted embodiment, the portion60 is less than or equal to half of the cross-sectional profile of the fiberoptic cable assembly10. In another embodiment, the portion60 is less than or equal to a third of the cross-sectional profile of the fiberoptic cable assembly10. The force F is applied to the portion60 so that the force F extends outwardly from thelengthwise axis35 of the fiberoptic cable assembly10. In the depicted embodiment ofFIG.7, the force F is generally perpendicular to thelengthwise axis35. In the subject embodiment, the force F extends outwardly from the portion60 in a first direction along the major axis36 of the fiberoptic cable assembly10. The force F can be applied with a tool such as pliers.

In the depicted embodiment ofFIG.7, the force F is generally perpendicular to an access line61. The access line61 passes through the first andsecond portions54,56 of theouter jacket16 and theaccess member50. In the subject embodiment, the access line61 passes through the center of theaccess member50.

In one embodiment, the portion60 is pulled in the first direction while a remaining portion62 of theouter jacket16 is held stationary. In another embodiment, the portion60 is pulled in a first direction while the remaining portion62 is pulled in a second direction that is opposite the first direction.

The force F applied to the portion60 of the fiberoptic cable assembly10 is of a magnitude that causes the first andsecond portions54,56 of the wall46 to tear. The force F is applied until a desired length L of the portion60 has been broken away from the remaining portion62 of the fiberoptic cable assembly10. Theaccess members50 disposed in the wall46 provide a discontinuity in the wall46. Unlike a ripcord, a force is not applied to theaccess members50 to create a break or tear in the wall. The force F is only applied to theouter jacket16.

With the portion60 removed from the fiberoptic cable assembly10, theoptical fibers12 in thefirst passage42 are accessible so that theoptical fibers12 can be spliced or so that a fiber optic breakout can be installed. In one embodiment, the portion60 of the fiberoptic cable assembly10 that has been broken away from the fiberoptic cable assembly10 is cut at opposite ends64a,64b of the portion60 where the portion60 is still engaged or connected to the fiberoptic cable assembly10.

Referring now toFIGS.8 and9, an alternate embodiment of a fiberoptic cable assembly210 is shown. The fiberoptic cable assembly210 includes a plurality ofoptical fibers212, a first reinforcing member214a and a second reinforcing member214b and anouter jacket216.

In the depicted embodiment, each of the first and second reinforcing members214a,214b has a transverse cross-sectional profile that is generally rectangular in shape. As shown atFIG.8, the first and second reinforcing members214a,214b have a transverse cross-sectional width that is greater than a transverse cross-sectional thickness.

The fiberoptic cable assembly210 includes a central longitudinal axis. In the depicted embodiment, theouter jacket216 has a non-circular outer profile. For example, as shown atFIG.8, when viewed in transverse cross-section, the outer profile of theouter jacket216 has a flat generally obround or rectangular shape. Theouter jacket216 includes amajor axis236 and aminor axis238. The major andminor axes236,238 are perpendicular to one another and intersect at acenter240 of theouter jacket216. A width of theouter jacket216 extends along themajor axis236 and a thickness of theouter jacket216 extends along theminor axis238. The width of theouter jacket216 is longer than the thickness.

Theouter jacket216 of the fiberoptic cable assembly210 defines afiber passage242 that extends along the central longitudinal axis. In the depicted embodiment, thefiber passage242 is disposed at thecenter240 of the fiberoptic cable assembly210. Theouter jacket216 further defines second andthird passages244a,244b. The second passage244a is adapted to receive the first reinforcing member214a while thethird passage244b is adapted to receive the second reinforcing member214b.

The second andthird passages244a,244b are generally aligned with themajor axis236. The second andthird passages244a,244b are disposed on opposite sides of theminor axis238.

The fiberoptic cable assembly210 includes awall246 disposed between anouter surface248 of theouter jacket216 and an inner diameter of thefiber passage242. Theouter jacket216 forms thewall246.

The fiberoptic cable assembly210 further includes a first access member250a and asecond access member250b. The first andsecond access members250a,250b are embedded in theouter jacket216. In the depicted embodiment, the first andsecond access members250a,250b are disposed in first and second access member passages252a,252b defined by thewall246. In the depicted embodiment, the first and second access member passages252a,252b are disposed on the same side of the fiberoptic cable assembly210 as divided by themajor axis236 but on opposite sides of the fiberoptic cable assembly210 as divided by theminor axis238.

Referring now toFIG.9, a method for accessing theoptical fibers212 of the fiberoptic cable assembly210 will be described. A bending force F_Bis applied to theouter jacket216 of the fiberoptic cable assembly210. The bending force F_Bis applied to the fiberoptic cable assembly210 so that afirst portion260 of theouter jacket216 is under tension while asecond portion262 is under compression. In the depicted embodiment, thefirst portion260 extends between the first andsecond access members250a,250b. In the subject embodiment, thefirst portion260 is disposed between the first and second reinforcing members214a,214b.

In the depicted embodiment, the bending force F_Bis applied to first and second sides266a,266b of the fiberoptic cable assembly210 so that thefirst portion260 is under tension while thesecond portion262 is under compression. The bending force F_Bapplied to the fiberoptic cable assembly210 causes thewall246 to tear. The bending force F_Bis applied until a desired length of thefirst portion260 has been broken away from the fiberoptic cable assembly210. With thefirst portion260 separated from the fiberoptic cable assembly210, theoptical fibers212 in thefiber passage242 are accessible so that theoptical fibers212 can be spliced or so that a fiber optic breakout can be installed.

Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that the scope of this disclosure is not to be unduly limited to the illustrative embodiments set forth herein.

Claims (32)

The invention claimed is:

1. A fiber optic cable assembly comprising:

an outer jacket defining a first passage and a second passage disposed adjacent to the first passage, the outer jacket including a wall disposed between an outer surface of the outer jacket and the first passage;

a plurality of optical fibers disposed in the first passage;

a reinforcing member disposed in the second passage; and

an access member disposed in the wall of the outer jacket;

wherein the wall includes a first portion that extends between the first passage and the access member and a second portion that extends between an the outer surface of the outer jacket and the access member, the first portion having a first thickness, the second portion having a second thickness, the first and second thicknesses being about equal, wherein the wall of the outer jacket has a third thickness that extends from the outer surface of the outer jacket to the first passage, and wherein the access member occupies at least 40 percent of the third thickness of the wall.

2. The fiber optic cable assembly ofclaim 1, wherein the outer jacket includes a major axis that extends through a center of the fiber optic cable assembly and a minor axis that extends through the center, the minor axis being generally perpendicular to the major axis.

3. The fiber optic cable assembly ofclaim 2, wherein the outer jacket has a width that extends along the major axis and a fourth thickness that extends along the minor axis, the width being greater than the fourth thickness.

4. The fiber optic cable assembly ofclaim 1, wherein the outer surface of the outer jacket is continuous.

5. The fiber optic cable assembly ofclaim 1, wherein the first thickness of the first portion of the wall is at most about 0.010 inches.

6. The fiber optic cable assembly ofclaim 1, wherein the plurality of optical fibers are loosely disposed in the first passage.

7. The fiber optic cable assembly ofclaim 1, wherein the plurality of optical fibers are disposed in a fiber bundle, the fiber bundle being disposed in the first passage.

8. The fiber optic cable assembly ofclaim 7, wherein the plurality of optical fibers are contra-helically served.

9. The fiber optic cable assembly ofclaim 1, wherein the reinforcing member has a cross-sectional width that is greater than a cross-sectional thickness so that the reinforcing member has a cross-sectional profile that is generally rectangular in shape.

10. A fiber optic cable assembly comprising:

an outer jacket defining a first passage and a second passage disposed adjacent to the first passage, the outer jacket including a major axis that extends through a center of the outer jacket and a minor axis that extends through the center, the minor axis being generally perpendicular to the major axis, the outer jacket including a first wall disposed between an outer surface of the outer jacket and the first passage and a second wall disposed between an the outer surface of the outer jacket and the first passage, wherein the first and second walls are disposed on opposite sides of the major axis;

a plurality of optical fibers disposed in the first passage;

a reinforcing member disposed in the second passage;

a first access member disposed in the first wall of the outer jacket, wherein the first wall includes a first portion that extends between the first passage and the first access member and a second portion that extends between the outer surface of the outer jacket and the first access member; and

a second access member disposed in the second wall of the outer jacket, wherein the second wall includes a third portion that extends between the first passage and the second access member and a fourth portion that extends between the outer surface of the outer jacket and the second access member, wherein the first wall has a first thickness that extends from the outer surface of the outer jacket to the first passage and the second wall has a second thickness that extends from the outer surface of the outer jacket to the first passage, and wherein the first access member occupies at least 40 percent of the first thickness of the first wall and the second access member occupies at least 40 percent of the second thickness of the second wall.

11. The fiber optic cable assembly ofclaim 10, wherein the outer jacket has a width that extends along the major axis and a third thickness that extends along the minor axis, the width being greater than the third thickness.

12. The fiber optic cable assembly ofclaim 10, wherein the first wall includes a first portion that extends between the first passage and the first access member and a second portion that extends between an outer surface of the outer jacket and the first access member, the first portion having has a first third thickness, the second portion having has a second fourth thickness, the first third and second fourth thicknesses being about equal.

13. The fiber optic cable assembly ofclaim 12, wherein the first third thickness of the first portion of the first wall is at most about 0.010 inches.

14. The fiber optic cable assembly ofclaim 12, wherein the second wall includes a first portion that extends between the first passage and the second access member and a second portion that extends between an outer surface of the outer jacket and the second access member, the first third portion having has a first fifth thickness, the second fourth portion having has a second sixth thickness, the first fifth and second sixth thicknesses being about equal.

15. The fiber optic cable assembly ofclaim 14, wherein the first fifth thickness of the first third portion of the second wall is at most about 0.010 inches.

16. The fiber optic cable assembly ofclaim 10, wherein the plurality of optical fibers are loosely disposed in the first passage.

17. A fiber optic cable assembly comprising:

an outer jacket defining a first passage and a second passage disposed adjacent to the first passage, the outer jacket including a major axis that extends through a center of the outer jacket and a minor axis that extends through the center, the minor axis being generally perpendicular to the major axis, the outer jacket including a wall disposed between an outer surface of the outer jacket and the first passage;

a plurality of optical fibers disposed in the first passage;

a reinforcing member disposed in the second passage;

a first access member disposed in the wall of the outer jacket, wherein the wall includes a first portion that extends between the first passage and the first access member and a second portion that extends between the outer surface of the outer jacket and the first access member; and

a second access member disposed in the wall of the outer jacket, wherein the wall includes a third portion that extends between the first passage and the second access member and a fourth portion that extends between the outer surface of the outer jacket and the second access member, wherein the first and second access members are disposed on the same side of the outer jacket as divided by the major axis, wherein the wall of the outer jacket has a thickness that extends from the outer surface of the outer jacket to the first passage, and wherein each of the first and second access members occupies at least 40 percent of the thickness of the wall.

18. The fiber optic cable assembly ofclaim 15, wherein the plurality of optical fibers are loosely disposed in the first passage.

19. A method for accessing the optical fibers of a fiber optic cable assembly, the method comprising:

applying a force to a portion of an outer jacket of a the fiber optic cable assembly, the force being applied in a direction that is outward from a lengthwise axis of the fiber optic cable assembly, the force being of a magnitude so that each of a first portion of a wall of the outer jacket disposed between an outer surface of the outer jacket and an access member disposed in the wall such that the access member occupies at least 40 percent of a thickness of the wall extending from the outer surface of the outer jacket to a first passage and a second portion of the wall disposed between the access member and a the first passage defined by the outer jacket tears;

pulling the portion of the outer jacket so that a desired length of the portion is separated from a remaining portion of the outer jacket; and

accessing the optical fibers in the first passage of the outer jacket.

20. A method for accessing the optical fibers of a fiber optic cable assembly, the method comprising:

providing a the fiber optic cable assembly having an outer jacket defining a passage containing an optical fiber, the outer jacket including a wall having a first portion that extends from the passage to an access member and a second portion that extends from the access member to an outer surface of the outer jacket, the wall of the outer jacket having a thickness that extends from the outer surface of the outer jacket to the passage, and the access member occupies at least 40 percent of the thickness of the wall; and

tensioning the outer jacket adjacent to the access member to tear the first and second portions without pulling on the access member.

21. The method ofclaim 20, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket matches an outer shape of the access member.

22. The method ofclaim 20, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket conforms to the access member.

23. The method ofclaim 20, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket has a diameter that is generally equal to an outer diameter of the access member.

24. The method ofclaim 20, wherein the access member is made of a material having a melting point temperature that is higher than a melting point temperature of a material of the outer jacket.

25. The method ofclaim 20, wherein the access member is made of a first material and the outer jacket is made of a second material.

26. The method ofclaim 20, wherein the outer surface of the outer jacket is continuous.

27. The method ofclaim 20, wherein the first and second portions have thicknesses that are about equal.

28. The method ofclaim 19, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket matches an outer shape of the access member.

29. The method ofclaim 19, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket conforms to the access member.

30. The method ofclaim 19, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket has a diameter that is generally equal to an outer diameter of the access member.

31. The method ofclaim 19, wherein the first and second portions have thicknesses that are about equal.

32. The fiber optic cable assembly ofclaim 1, wherein the outer jacket defines an access member passage that extends along a length of the fiber optic cable assembly, and wherein the access member passage of the outer jacket matches an outer shape of the access member.

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