阅读说明：本技术 柔性光纤带及其形成方法 (Flexible optical fiber ribbon and method of forming the same ) 是由 E·法拉赫穆罕默迪 C·N·安德森 B·G·里施 于 2019-08-15 设计创作，主要内容包括：柔性光纤带及其形成方法。一种光纤线缆,其包括多个柔性带、多个第一结合区域和第二结合区域。多个柔性带中的每一个柔性带均包括多根光纤。多根光纤中的相邻光纤通过多个第一结合区域中的一个第一结合区域附接于彼此。第二结合区域使多个柔性带中的第一柔性带与多个柔性带中的第二柔性带接合。(Flexible optical fiber ribbons and methods of forming the same. A fiber optic cable includes a plurality of flexible ribbons, a plurality of first bonding regions, and a second bonding region. Each of the plurality of flexible ribbons includes a plurality of optical fibers. Adjacent ones of the plurality of optical fibers are attached to each other by one of a plurality of first bonding regions. The second bonding region joins a first flexible strap of the plurality of flexible straps with a second flexible strap of the plurality of flexible straps.)

1. An optical fiber cable, comprising:

a plurality of flexible ribbons, each of the plurality of flexible ribbons comprising a plurality of optical fibers;

a plurality of first bonding regions through which adjacent ones of the plurality of optical fibers are attached to each other; and

a second bonding region joining a first flexible strap of the plurality of flexible straps with a second flexible strap of the plurality of flexible straps.

2. The cable according to claim 1, wherein the second bonding region has a bonding strength lower than a bonding strength of one of the plurality of first bonding regions.

3. The cable of claim 1, wherein the first plurality of bonding regions are disposed on a first side of the plurality of flexible strips and the second plurality of bonding regions are disposed on a second side of the plurality of flexible strips, wherein the second side is opposite the first side.

4. The cable of claim 1, wherein the plurality of optical fibers extend along a length of the fiber optic cable, wherein the plurality of first bonding regions have a first pattern, and wherein the second bonding regions extend through substantially an entire length of the fiber optic cable.

5. The cable of claim 4, wherein the second bonding region has a second pattern different from the first pattern.

6. The cable of claim 5, wherein the second pattern has a characteristic different from a characteristic of the first pattern, wherein the characteristic comprises an amplitude, a phase, a pitch, a combined length, or a duty cycle.

7. The cable of claim 1, wherein the second bonding region bonds exactly two of the plurality of optical fibers together.

8. The cable of claim 1, wherein the second bonding region splices optical fibers from different ribbons of the plurality of flexible ribbons and splices optical fibers within a single ribbon of the plurality of flexible ribbons.

9. The cable of claim 1, wherein the second bonding region fills a first cross-connection between a first one of the plurality of optical fibers and a second one of the plurality of optical fibers, and the second bonding region fills a second cross-connection between the second one of the plurality of optical fibers and a third one of the plurality of optical fibers.

10. The cable of claim 1, wherein the second bonding region comprises a first portion, a second portion, and a third portion arranged in a wave or zigzag pattern, the first portion splicing a last optical fiber of a first flexible ribbon of the plurality of flexible ribbons with a first optical fiber of a second flexible ribbon of the plurality of flexible ribbons, the second portion splicing the last optical fiber of the first flexible ribbon with a previous optical fiber of the first flexible ribbon, and the third portion splicing the first optical fiber of the second flexible ribbon with a second optical fiber of the second flexible ribbon.

11. A method of forming the fiber optic cable of claim 1, the method comprising:

forming the plurality of flexible ribbons by attaching the plurality of optical fibers using the plurality of first bonding regions; and

forming a flex tape assembly by attaching the plurality of flex tapes using a plurality of second bonding areas comprising the second bonding areas, wherein adjacent flex tapes of the plurality of flex tapes are attached to each other by one of the plurality of second bonding areas.

12. The method of claim 11, wherein forming the plurality of flexible straps comprises:

configuring the plurality of optical fibers;

distributing a matrix material at a cross-connection portion between the plurality of optical fibers; and

curing the matrix material.

13. The method of claim 11, wherein forming the flex tape assembly comprises:

configuring the plurality of flexible straps;

dispensing a matrix material at cross-connects between the plurality of flexible strips; and

curing the matrix material.

14. The method of claim 11,

forming the plurality of flexible ribbons includes dispensing a first matrix material at cross-connections between the plurality of optical fibers at a first side of the plurality of optical fibers; and

forming the flexible ribbon assembly includes dispensing a second matrix material at cross-connects between the plurality of flexible ribbons on a second side of the plurality of optical fibers, wherein the second side is opposite the first side.

15. The method of claim 11, wherein a buffer tube is formed that includes the flexible tape assembly, and the optical fiber cable is formed that includes the buffer tube.

Technical Field

The present application relates generally to fiber optic cables and, in particular embodiments, to flexible fiber optic ribbons and methods of forming the same.

Background

Optical fibers are very small diameter glass filaments that are capable of transmitting optical signals at very high speeds over long distances and have relatively low signal losses relative to standard copper wire networks. Accordingly, optical fiber cables are widely used for long distance communications, and have replaced other technologies such as satellite communications, standard cable communications, and the like. In addition to long-distance communications, optical fibers are used in many applications such as medicine, aviation, computer data servers, and the like.

There is an increasing need in many applications for optical cables capable of transmitting high data rates while occupying a minimum amount of space. Such a need may arise, for example, in data servers where space for optical fibers is a critical limiting factor. In particular, data servers are handling an increasing amount of data requiring increased connections to the data servers. With the expansion of group computing (crowdcomputing), the data capacity of global data centers has increased dramatically, as has the demand for high fiber counts and high density fiber optic cables. However, the maximum size of the fiber optic cable is limited by the size of the conduit through which the cable must pass. Pressing a conventional cable through a conduit is not a viable option. This is because, although conventional optical fibers can transmit more data than copper wires, they are also more susceptible to damage during installation. The performance of the optical fibers within the cable is very sensitive to bending, buckling or compressive stresses. Excessive compressive stresses during manufacturing, cable installation, or repair can adversely affect the mechanical and optical performance of conventional optical fibers. Therefore, it is necessary to reduce the diameter and weight of the cable. Reducing the diameter and weight of the cable will enable the use of existing facilities (such as underground pipes or utility poles) and will reduce cable costs and installation costs.

In addition, in order to shorten the operation time of mid-span access (mid-span access) or cable connection, a cable structure having ease of use is required.

Disclosure of Invention

According to an embodiment of the present application, a fiber optic cable includes a plurality of flexible ribbons, a plurality of first bonding regions, and a second bonding region. Each of the plurality of flexible ribbons includes a plurality of optical fibers. Adjacent ones of the plurality of optical fibers are attached to each other by one of the plurality of first bonding regions. A second bonding region joins a first flexible strap of the plurality of flexible straps with a second flexible strap of the plurality of flexible straps.

According to another embodiment of the present application, a fiber optic cable includes a plurality of flexible ribbons (the plurality of flexible ribbons including a first flexible ribbon and a second flexible ribbon), a plurality of first bonded regions and a plurality of second bonded regions, the second bonded regions including a first discrete region and a second discrete region. Each of the plurality of flexible ribbons includes a plurality of optical fibers. Adjacent ones of the plurality of optical fibers are attached to each other by one of a plurality of first bonding regions. The first discrete region bonds a last optical fiber of a first flexible ribbon of the plurality of flexible ribbons with a first optical fiber of a second flexible ribbon of the plurality of flexible ribbons, and the first discrete region is disposed at a first intersection region between the last optical fiber and the first optical fiber. The second discrete region is spaced apart from the first discrete region by the first pitch, the second discrete region bonds the last optical fiber to the first optical fiber, and the second discrete region is disposed at a second intersection region between the last optical fiber and the first optical fiber.

According to another embodiment of the present application, a method of forming a fiber optic cable includes forming a plurality of flexible ribbons by attaching a plurality of optical fibers using a plurality of first bonding regions, wherein adjacent optical fibers of the plurality of optical fibers are attached to each other by one of the plurality of first bonding regions. The method may further include forming a flex tape assembly by attaching a plurality of flex tapes using a plurality of second bond regions, wherein adjacent flex tapes of the plurality of flex tapes are attached to each other by one of the plurality of second bond regions.

Drawings

For a more complete understanding of the present application and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

1A-1C illustrate a unitary flexible ribbon of a fiber optic cable according to an embodiment of the present application, wherein FIG. 1A illustrates a top view of the unitary flexible ribbon including a continuous bonding area between adjacent flexible ribbons, FIG. 1B illustrates a bottom view of the unitary flexible ribbon illustrating the continuous bonding area, and FIG. 1C illustrates corresponding cross-sectional areas of the unitary flexible ribbons illustrated in FIGS. 1A-1B;

fig. 2A-2B illustrate a unitary flexible ribbon of a fiber optic cable according to an embodiment of the present application, wherein fig. 2A illustrates a top view of the unitary flexible ribbon including a continuous bonding area having a wave pattern, and fig. 2B illustrates a bottom view of the unitary flexible ribbon illustrating the continuous bonding area;

fig. 3A-3C illustrate a unitized flexible ribbon of fiber optic cable according to an embodiment of the present application. FIG. 3A shows a top view of a unitized flexible ribbon of fiber optic cable. Fig. 3B illustrates a bottom view of the unitized flexible tape of the fiber optic cable. FIG. 3C illustrates corresponding cross-sectional areas of the unitized flexible tape shown in FIGS. 3A-3B;

4A-4B illustrate a unitary flexible ribbon of a fiber optic cable according to an embodiment of the present application, wherein FIG. 4A illustrates a top view of the unitary flexible ribbon including intermittent bonding areas and FIG. 4B illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bonding areas;

fig. 5A-5B illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 5A illustrates a top view of the unitary flexible ribbon including intermittent bond areas having an alternative pattern, and fig. 5B illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bond areas;

fig. 6A-6C illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 6A illustrates a top view of the unitary flexible ribbon including a discontinuous bond area having yet another alternative pattern, fig. 6B illustrates a bottom view of the unitary flexible ribbon illustrating the discontinuous bond area, and fig. 6C illustrates a bottom view of the unitary flexible ribbon illustrating the discontinuous bond area in the alternative embodiment;

fig. 7A-7B illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 7A illustrates a top view of the unitary flexible ribbon including intermittent bond areas having yet another alternative pattern, and fig. 7B illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bond areas;

fig. 8A-8E illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 8A illustrates a top view of a unitary flexible ribbon including intermittent bond regions having a first pattern (pattern), fig. 8B illustrates a top view of a unitary flexible ribbon including intermittent bond regions having a second, different pattern, fig. 8C illustrates a top view of a unitary flexible ribbon including intermittent bond regions having a third, different pattern, fig. 8D illustrates a top view of a unitary flexible ribbon including intermittent bond regions having a fourth, different pattern, and fig. 8E illustrates a top view of a unitary flexible ribbon including intermittent bond regions having a square wave, different pattern;

FIGS. 9A-9C show cross-sectional views of a unitized flexible tape, buffer tube, and optical cable according to an embodiment of the present application, where FIG. 9A shows the unitized flexible tape folded together according to an embodiment of the present application, FIG. 9B shows a cross-sectional view of a buffer tube formed using a plurality of flexible tape assemblies, and FIG. 9C shows a cross-sectional view of an optical cable including the plurality of buffer tubes of FIG. 9B;

fig. 10A-10E illustrate a unitized flexible ribbon at various stages of manufacture according to embodiments of the present application, where fig. 10A illustrates a process of assembling the flexible ribbon from a plurality of optical fibers, fig. 10B illustrates a plurality of flexible ribbons during formation of a first bond region at a top side, fig. 10C (similar to fig. 10A) illustrates a flexible ribbon assembly formed from a plurality of flexible ribbons according to embodiments of the present invention, fig. 10D illustrates a cross-sectional view of a plurality of flexible ribbons during formation of a second bond region at an opposite bottom side, and fig. 10E illustrates a top view of a plurality of flexible ribbons during formation of a second bond region along a predetermined pattern at the bottom side.

Fig. 11A-11B illustrate an alternative embodiment of a unitized flex tape at various stages of manufacture (where the optical tape is stationary during bonding), where fig. 11A illustrates a plurality of flex tapes during formation of a first bonding region on a top side and fig. 11B illustrates a cross-sectional view of a plurality of flex tapes during formation of a second bonding region on an opposite bottom side.

Detailed Description

The present preferred embodiments (including their manufacture and use) are discussed in detail below. It should be appreciated, however, that the present application provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention. These specific embodiments do not limit the scope of the invention.

The present application will be described with reference to exemplary embodiments in a particular context (i.e., the construction and manufacture of a unitary flexible ribbon comprising a plurality of optical fibers).

In various embodiments, a unitized structure for a flexible ribbon of a fiber optic cable is disclosed. Fiber optic cables include a number of such ribbons, where each ribbon may be made of a plurality of optical fibers (e.g., twelve to sixteen optical fibers). Embodiments of the present application describe joining flexible straps using a pattern of matrix material to unitize the straps to form a flexible strap assembly. For example, a flexible ribbon of two twelve optical fibers becomes a single, unitized ribbon of twenty-four optical fibers.

Embodiments of the present application provide advantages in manufacturing cables for flexible tapes, as fewer individual components need to be stranded and injected into the cable during the tape buffering process. For example, embodiments of the present application can reduce the amount of pay-off during ribbon buffering, where a large number of ribbon spools (bobbins) are used for high fiber count cables. Due to the enhanced flexibility provided by the flex tape assembly, a greater number of optical fibers can be enclosed within each buffer tube, enabling a higher density of optical fibers. In addition, users/installers of these cables would benefit from the reduction in complexity. For example, when a user/installer removes a modular ribbon or a flexible ribbon assembly from a buffer tube, fewer ribbons need to be handled and easier steps need to be taken for high volume splicing (mass splicing) of optical fibers. As shown, instead of exposing 144 flexible ribbons (each having twelve optical fibers) from the buffer tube, the user/installer would need to handle only 72 unitized flexible ribbons with 2 x 12 optical fibers in each unitized flexible ribbon. This will ease access to the closure before splitting the ribbon and splicing the fibers.

The flexible optical tape assembly will first be described in the top, bottom and cross-sectional views of fig. 1A-C, having a continuous bonding area between its constituent flexible optical tapes. Next, a number of additional structural embodiments of the ribbon assembly will be described, with the shapes and locations of the bonding areas applied between the constituent optical fibers differing in fig. 2A-2B, 3A-3C, 4A-4B, 5A-5B, 6A-6C, 7A-7B, and 8A-8E. An optical cable design implementing an embodiment of the present application will be described using fig. 9A to 9C. A method of manufacturing a unitized flexible optical tape will be described with reference to fig. 10A to 10E and fig. 11A to 11B. All of the figures, except fig. 9A-9C, illustrate the flexible strap in a rolled out or planar configuration. In a cable, as shown for example in fig. 9A-9C, the flexible tape is rolled or coiled together in the buffer tube.

Fig. 1A to 1C illustrate an optical cable according to an embodiment of the present application. FIG. 1A shows a top view of a unitized flexible ribbon of fiber optic cable. FIG. 1B illustrates a bottom view of a unitized flexible ribbon of fiber optic cable. Fig. 1C shows corresponding cross-sectional areas of the unitized flexible tape shown in fig. 1A-1B.

Referring to fig. 1A, the fiber optic cable includes a flex tape assembly 25, the flex tape assembly 25 including a plurality of flex tapes, such as a first flex tape 50 and a second flex tape 60. In various embodiments, a plurality of optical fibers are stacked or bundled together to form a single flexible ribbon. However, unlike conventional ribbons that are stacked and packaged together, in various embodiments, the optical fibers are loosely attached (in an unpackaged, non-rigid manner) such that the ribbon remains flexible to configure into different shapes. For example, as shown in the cross-sectional view of FIG. 1C, first flexible ribbon 50 includes a first set of optical fibers 51-58, and second flexible ribbon 60 includes a second set of optical fibers 61-68. Although only eight optical fibers are shown, in various embodiments, each flexible ribbon may include a greater or lesser number of optical fibers. For example, in one embodiment, first flexible strip 50 and second flexible strip 60 include six optical fibers. However, in another embodiment, first flexible strip 50 and second flexible strip 60 may include twelve or sixteen optical fibers. In other words, the number of fibers may vary depending on the application.

Referring to fig. 1A and 1C, adjacent optical fibers are attached together at a first bonding region 30. As best shown in fig. 1C, the first bonding region 30 fills the gap between adjacent optical fibers, such as seventh optical fiber 57 and eighth optical fiber 58. In addition, a first bonded region 30 is formed on a first side 21 of the first flexible strip 50 opposite the second side 22.

Referring to fig. 1A, adjacent first bonding regions 30 of the spliced optical fibers are separated from each other by a first pitch p 41. Although the first pitch p41 does not vary within the cable as shown in fig. 1A, in some embodiments, the first pitch p41 may not be constant within the cable. In order to maintain a constant pitch, the first bonding region 30 has a duty cycle (duty cycle) of 50%, in other words, is formed only during half of the wave period. In other words, at 50% of the space junctions, there are bonding regions only along the alternating intersections between adjacent fibers of the first pattern 41. At a duty cycle of 100%, all the intersections between adjacent fibers along the first pattern 41 have a bonded area.

The first pitch p41 may vary, for example, from about 10mm to about 500mm depending on the application. In one or more embodiments, the first pitch p41 may vary from about 30mm to about 100 mm.

The first bond area 30 extends into the page of fig. 1C and may have a first bond length b41 as shown in fig. 1A. The first bond length b41 may vary, for example, from about 1mm to about 50mm, depending on the application. In one or more embodiments, the first bond length b41 may vary from about 5mm to about 20 mm.

Each first bonding area 30 is separated from the nearest first bonding area to which a different fiber optic cable is spliced by a first adjacent distance n 41.

In various embodiments, these distances (first pitch p41, first bond length b41, and first adjacent distance n41) will be varied to achieve a predetermined set of mechanical properties of the tape (such as strength, flexibility, or rigidity) and to achieve a target production cost and throughput.

In addition, the first pattern 41 is formed by plotting a curve passing through the nearest neighboring region of the first bonding region 30. In the illustration, the first pattern 41 includes a wave pattern. The wave pattern may be illustrated using a first pitch p41, a first bond length b41, and a first adjacent distance n 41. Alternatively, the wave pattern may be illustrated using a wavelength (first pitch p41) and a first amplitude a41 together with a first bond length b 41. In various embodiments, the wave pattern formed by the first bonding areas 30 may include any type of wave, such as a square wave, a sine wave, a cosine wave, a triangular wave, and the like.

However, in various embodiments, the first bonding regions 30 may be configured in other patterns. Some of these alternative patterns will be further explained in the following embodiments.

In various embodiments, the first bonding region 30 may include a matrix material that acts as a bonding agent between adjacent optical fibers. In one embodiment, the matrix material of the first bonding region 30 may include an acrylic-based, light-cured, quick-dry adhesive, such as a UV-cured acrylate material. In another embodiment, the matrix material of the first bonding region 30 may include a cured resin. In alternative embodiments, the first bonded area 30 may include other bonding materials, such as thermoplastic materials.

Referring to fig. 1A-1B, first flexible strap 50 is attached to second flexible strap 60 at second bonded region 35. In various embodiments, the second bonding region 35 is formed on the second side 22, which second side 22 is opposite the first side 21 on which the first bonding region 30 is formed. This is illustrated in fig. 1A, where the solid lines and the white areas show the first bonding areas 30 located at the first side 21. In contrast, the dashed lines show the second bonding areas 35 at the second side 22. In fig. 1B, which gives a bottom view, the first pattern 41 of first bonding areas 30 at the first side 21 is shown in dashed lines and the second bonding areas 35 at the second side 22 are shown in solid lines and white areas. This convention is maintained in the remaining figures. However, as will be clear from the description that follows, the first and second sides 21, 22 are not planar in the cable due to the folding of the flexible tape. In other words, the first side 21 and the second side 22 are in the same plane before folding and merging the cable. Once within the cable, however, the tape is folded so the first and second sides 21, 22 may not share a common plane.

Fig. 1A-1C illustrate an embodiment in which the second bonded region 35 extends linearly and continuously between adjacent flexible strips, such as first flexible strip 50 and second flexible strip 60. As shown in fig. 1B, second bonding region 35 splices adjacent optical fibers of first flexible strip 50 and second flexible strip 60. This is also shown in fig. 1C, where the second bonding region 35 fills the gap between the eighth optical fiber 58 from the first set of optical fibers 51-58 of the first flexible strip 50 and the first optical fiber 61 from the second set of optical fibers 61-68 of the second flexible strip 60.

Additionally, a second bond area 35 is formed on the second side 22 of the flex tape assembly 25 opposite the first bond area 30. Thus, in this embodiment, the flexible strip assembly 25 includes a first flexible strip 50 and a second flexible strip 60 that are unitized by a linearly continuous second bonding region 35.

However, in various embodiments, a plurality of second bonding regions 35 may be used instead of a single second bonding region, and the plurality of second bonding regions 35 may be configured in other patterns. Some of these alternative patterns will be further explained in the following embodiments.

Advantageously, the flex tape assembly 25 maintains a high degree of flexibility because the bonding area of the plurality of second bonding areas 35 is much smaller than conventional packages that cover all of the optical fibers. In addition, the smaller bonding area results in less bonding strength which makes it easier for the flexible tape to be separated into smaller two or three sets for mass fusion (mass fusion splicing). Preferably, the bonding strength of the second bonding region 35 is less than the bonding strength of the first bonding region 30. This creates a preferential separation between the flex tapes as the flex tape assembly 25 is divided into two or three sets of flex tapes for mass fusion splicing and prevents the optical fiber or fibers of one flex tape from remaining attached to an adjacent flex tape. The bonding strength of the second bonding areas 35 (as well as the first bonding areas 30) can be adjusted by the length of the bonding areas, the degree of cure of the flexible tape surface, or the composition of the bonding material, such as the presence or amount of tackifier.

In various embodiments, the bonding strength of the first bonding region 30 will range from 0.1N to 1.5N, preferably between 0.1N and 0.3N, while the bonding strength of the second bonding region 35 (while being less than the bonding strength of the first bonding region) will range from 0.01N to 0.3N, preferably between 0.01N and 0.1N, when measured using techniques such as the T-peel test.

In a T-peel test, an individual fiber or group of fibers from the end of a ribbon is clamped in the grip of a tensile tester (e.g., Instron 5567), while the remaining fibers from the same end of the ribbon are clamped in the opposite grip of the tensile tester, and the force separating the two is measured. In this T-peel test, the force to break a single bond was measured.

Fig. 2A to 2B show another embodiment of the present application, in which the second bonding region 35 has a continuous wave pattern. Fig. 2A shows the first side 21 of the flexible tape assembly 25 with the first bond areas 30 applied in the first pattern 41 having the first pitch p41 described using fig. 1A. Fig. 2B shows the bottom surface of the flex tape assembly 25 with the second bonding areas 35 formed continuously along the undulating pattern.

In the embodiment shown in fig. 2A-2B, the second bonding region 35 includes a first portion S35-1 similar to the previous embodiment, the first portion S35-1 splicing the eighth optical fiber 58 from the first set of optical fibers 51-58 of the first flexible ribbon 50 with the first optical fiber 61 from the second set of optical fibers 61-68 of the second flexible ribbon 60. However, unlike the previous embodiment, the second bonding region 35 also includes a second portion S35-2 and a third portion S35-3 that splice adjacent fibers within the same flex tape, the second and third portions S35-2 and S35-3. For example, in the illustration, the second portion S35-2 splices a seventh optical fiber 57 from the first group of optical fibers 51-58 of the first flexible ribbon 50 with an eighth optical fiber 58 from the first group of optical fibers 51-58 of the first flexible ribbon 50. Similarly, the third section S35-3 splices the first optical fiber 61 from the second set of optical fibers 61-68 of the second flexible ribbon 60 with the second optical fiber 62 from the second set of optical fibers 61-68 of the second flexible ribbon 60.

As shown in fig. 2B, the second bonding area 35 has a waveform shape having a second amplitude a 2. In other embodiments, the second bonding region 35 may have a greater amplitude (than shown in fig. 2B) such that more fibers are spliced through the second bonding region 35. In other words, as the second amplitude a2 of the continuous wave pattern increases, the second bonding region 35 will splice a greater number of optical fibers in the first and second flexible strips 50, 60 together.

In various embodiments, the shape formed by the second bonding area 35 may include any type of wave, such as a square wave, a sine wave, a cosine wave, a triangular wave, and the like. In other embodiments, the shape formed by the second bonding region 35 may be any shape, such as a "zig-zag" shape.

Fig. 3A-3C illustrate fiber optic cables according to embodiments of the present application, wherein the second bonding region has a greater width to splice multiple optical fibers together. FIG. 3A shows a top view of a unitized flexible ribbon of fiber optic cable. Fig. 3B illustrates a bottom view of the unitized flexible tape of the fiber optic cable. Fig. 3C illustrates corresponding cross-sectional areas of the unitized flexible tape shown in fig. 3A-3B.

In contrast to the embodiment in fig. 2A to 2B, the second bonding region 35 is linear and continuous similar to the embodiment in fig. 1A to 1C. However, unlike the embodiment described using fig. 1A to 1C, in this embodiment, the second bonding region 35 is wider in order to bond more optical fibers together.

Thus, this embodiment may be similar to fig. 1A-1C in that a linearly continuous second bonding region 35 is arranged at the second side 22 for engaging the first flexible strip 50 with the second flexible strip 60. However, unlike the embodiment of fig. 1A-1C, in this embodiment, the second bonding region 35 may be wider with a width w35 overlapping more than just two optical fibers. In the illustration, the second bonding region 35 has a width w35 that overlaps the seventh optical fiber 57 from the first set of optical fibers 51-58 of the first flexible strip 50, the eighth optical fiber 58 from the first set of optical fibers 51-58 of the first flexible strip 50, the first optical fiber 61 from the second set of optical fibers 61-68 of the second flexible strip 60, and the second optical fiber 62 from the second set of optical fibers 61-68 of the second flexible strip 60.

The second bonding region 35 may also be thicker to achieve partial encapsulation of the plurality of optical fibers. Although this embodiment may not be as flexible as the embodiment of fig. 1A-1C, the partial encapsulation provided by the second bonding region 35 may advantageously have improved mechanical strength in some applications.

Fig. 4A-4B illustrate a unitized flexible ribbon of fiber optic cable according to an embodiment of the present application. Fig. 4A shows a top view and fig. 4B shows a bottom view of a unitary flexible strip including intermittent bond regions.

In other embodiments, the second bonding region 35 may be applied in a similar manner to the first bonding region 30 described in the previous embodiments. In other words, instead of a continuous second bonding area 35 (as explained in fig. 1A to 3C above), a plurality of second bonding areas 35 may be used to form the flex tape assembly 25. Each of the plurality of second bonding regions 35 is shorter than the length of the respective optical fiber.

Referring to fig. 4A-4B, in one embodiment, first flexible strap 50 and second flexible strap 60 are joined together at second side 22. Fig. 4B shows a plurality of second bonding regions 35 applied between adjacent optical fibers of first flexible strip 50 and second flexible strip 60.

As shown in fig. 4B, the plurality of second bonding regions 35 may have a second bonding length B42. The second bond length b42 may vary, for example, from about 1mm to about 50mm, depending on the application. In one or more embodiments, the second combined length b42 may vary from about 5mm to about 20 mm.

In the embodiment shown in fig. 4B, adjacent bonding regions of the plurality of second bonding regions 35 are separated by a second pitch p 42. The second pitch p42 may vary, for example, from about 10mm to about 250mm depending on the application. In one or more embodiments, the second pitch p41 may vary from about 30mm to about 80 mm. In one embodiment, the second pitch p41 varies from 40mm to 50 mm.

In addition, a curve is drawn through the nearest neighboring region of the second bonding region 35 to form a second pattern 42. As shown in fig. 4B, the second pattern 42 includes a wave pattern. Similar to the first pattern 41, the second pattern 42 may also optionally be illustrated using a second pitch p42 and a second combined length b 42.

In various embodiments, these distances (second pitch p42 and second combined length b42) will vary to achieve a predetermined set of mechanical properties (such as strength, flexibility, or rigidity) of the flex tape assembly 25 and to achieve a target production cost and production capacity.

Fig. 5A-5B illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 5A illustrates a top view of the unitary flexible ribbon including intermittent bond areas (which have a different alternative pattern than fig. 4A-4B), wherein fig. 5B illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bond areas;

unlike the previous embodiment of fig. 4A to 4B, in the present embodiment, the plurality of second bonding regions 35 are arranged in a wave shape in such a manner that more than two optical fibers are bonded together. Referring to fig. 5A to 5B, in one embodiment, the plurality of second bonding areas 35 follow the third pattern 43.

Referring to fig. 5B, adjacent second bonding regions 35 where the same optical fiber is spliced are separated from each other by a third pitch p 43. In order to maintain a constant pitch, the plurality of second bonding regions 35 have a duty cycle of 50%, in other words, are formed only during half of the wave period. Depending on the application, the third pitch p43 may vary, for example, from about 10mm to about 250 mm. In one or more embodiments, the third pitch p43 may vary from about 30mm to about 100 mm. In one embodiment, the third pitch p43 may vary from 40mm to 50 mm.

The plurality of second bonded regions 35 includes a first discrete region R₁A second discrete region R₂. First discrete region R₁And a second discrete region R₂The last optical fiber (eighth optical fiber 58) of the first flexible strip 50 is spliced to the first optical fiber 61 of the second flexible strip 60. First discrete region R₁And a second discrete region R₂A first crossing region and a second crossing region arranged between the last optical fiber and the first optical fiber 61. Second discrete region R₂And a first discrete region R₁Spacing third sectionDistance p 43.

Unlike the previous embodiment, in the present embodiment, the plurality of second bonding regions 35 includes a third discrete region R to which other optical fibers are connected₃. Third discrete region R₃Splicing the first optical fiber 61 of the second flexible strip 60 with the second optical fiber 62 of the second flexible strip 60, and the third discrete region R₃A third crossing region disposed between the first optical fiber 61 and the second optical fiber 62.

Each of the plurality of second bonding regions 35 may have a third bonding length b 43. Depending on the application, the third bond length b43 may vary, for example, from about 1mm to about 50 mm. In one or more embodiments, the third combined length b43 may vary from about 5mm to about 20 mm. In the embodiment shown in fig. 5A and 5B, the first coupling length B41 is substantially the same as the third coupling length B43.

Each of the plurality of second bond areas 35 is separated from the nearest second bond area that splices a different fiber optic cable by a third adjacent distance n 43. In various embodiments, these distances (third pitch p43, third bond length b43, and third adjacent distance n43) will vary to achieve a predetermined set of mechanical properties of the ribbon (such as strength, flexibility, or rigidity) and to achieve a target production cost and capacity.

In addition, a curve drawn through the nearest neighboring region of the plurality of second bonding regions 35 forms the third pattern 43. In the illustration, the third pattern 43 includes a wave pattern. The waveform pattern of the third pattern 43 may be illustrated using the third pitch p43, the third bonding length b43, and the third adjacent distance n 43. Alternatively, the waveform pattern may be illustrated using a wavelength (third pitch p43) and a third amplitude a43 together with a third bonding length b 43. In various embodiments, the pattern formed by the second bonding areas 35 may include any type of wave, such as a square wave, a sine wave, a cosine wave, a triangular wave, and the like.

However, in various embodiments, the first bonding regions 30 may be configured in other patterns. Some of these alternative patterns will be further explained in the following embodiments.

In the embodiment shown in fig. 5A, the third pattern 43 has the same phase as the first pattern 41 and the third pitch p43 has the same pitch as the first pitch p41 of the first pattern 41, the first pattern 41 describing the first bonded area 30 on the first side 21 of the flexible tape assembly 25. In addition, in the present embodiment, the third amplitude a43 of the third pattern 43 is smaller than the first amplitude a41 of the first pattern 41. In other embodiments, the third amplitude a43 of the third pattern 43 may be varied to achieve different properties of the flexible band assembly 25, such as flexibility or bond strength.

Fig. 6A-6C illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 6A illustrates a top view of the unitary flexible ribbon including intermittent bond regions having yet another alternative pattern, fig. 6B illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bond regions, and fig. 6C illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bond regions in the alternative embodiment.

This embodiment may be similar to the embodiment described using fig. 5A-5B, except that the plurality of second bonding regions 35 are configured as different wave patterns schematically shown as fourth patterns 44. In particular, in this embodiment, the fourth pattern 44 has the same phase, pitch, and amplitude as the first pattern 41. Therefore, as shown in fig. 6B, the first amplitude a41 is the same as the fourth amplitude, and the first pitch p41 is the same as the fourth pitch p 44.

In fig. 6C, the fourth pattern 44 has the same pitch and amplitude as the first pattern 41, compared to fig. 6B. However, the duty ratio has a phase difference with respect to the first pattern 41 (e.g., shown in fig. 5A). This is also evident by comparing fig. 6B and 6C, the duty cycle of the embodiment in fig. 6C having a phase difference of 180 ° with respect to the duty cycle of the embodiment in fig. 6B.

As a further illustration, the first bonding region 30 at the first side 21 and the second bonding region 35 at the second side 22 of the embodiment in fig. 6A-6C have different bonding lengths. In the embodiment shown in fig. 6A and 6B, the first combined length B41 is substantially different from the fourth combined length B44. In one embodiment as shown in fig. 6B-6C, the fourth bond length B44 is longer than the first bond length B41, e.g., 20%. In another embodiment, the fourth bond length b44 is shorter than the first bond length b 41.

Fig. 7A-7B illustrate a unitary flexible ribbon of a fiber optic cable according to an alternative embodiment of the present application, wherein fig. 7A illustrates a top view of the unitary flexible ribbon including intermittent bond areas having yet another alternative pattern, and fig. 7B illustrates a bottom view of the unitary flexible ribbon illustrating the intermittent bond areas;

in this embodiment, the bonding area is configured at a duty cycle of 100% compared to the previous embodiment. See, for example, first bond area 30 on first side 21 of flex tape assembly 25 in fig. 7A and second bond area 35 on second side 22 of flex tape assembly 25 in fig. 7B. As a result, due to the wavy patterns of the first and fifth patterns 41 and 45, in this embodiment, the optical fiber in the flexible central region is more rigidly attached than the optical fiber at the outer periphery of the wavy patterns. For example, as a result, the attachment between first flexible strap 50 and second flexible strap 60 may be more secure at the intersection between the straps. In another embodiment, the first bonding region 30 may be configured at a 50% duty cycle (e.g., as shown in fig. 1A, 2A, 3A, 4A, 5A, 6A), while the second bonding region may be configured at a 100% duty cycle.

In addition, the fifth pattern 45 shown in fig. 7B may have a different phase from the first pattern 41 shown in fig. 7A while maintaining a similar pitch and amplitude to the first pattern 41.

Fig. 8A-8D illustrate top views of unitized flexible straps according to various alternative embodiments of the present application. The corresponding top view is not shown and the dashed lines show features on the opposite side.

Referring to fig. 8A, the plurality of second bonding areas 35 are configured in another optional sixth pattern 46. For clarity, only some of the plurality of second bonding regions 35 are shown in fig. 8A.

The sixth pattern 46 has a magnitude greater than that shown in the previous embodiment such that a plurality of second bond areas 35 are applied across the connection of each (or substantially all) optical fiber on the bottom side of the flex tape assembly 25. In this embodiment, the first bonding length b41 of the first bonding region 30 may be substantially equal to the sixth bonding length b46 of the second bonding region 35. In other embodiments, the first bond length b41 of the first bond region 30 may be different than the sixth bond length b46 of the second bond region 35. Although the first bonding areas 30 are arranged at a duty cycle of 100% along the first pattern 41, in other embodiments, a different duty cycle may be selected. Some options include 25%, 50%, and 75%.

Fig. 8B shows another alternative embodiment of the present application having a "zig-zag" pattern. Referring to fig. 8B, the plurality of second bonding regions 35 are configured in another optional seventh pattern 47. Also, for clarity, only some of the plurality of second bonding regions 35 are shown in FIG. 8B.

In one embodiment, the seventh pattern 47 may have a large amplitude such that one of the plurality of second bonding areas 35 is used to attach the cross-connect of each (or substantially all) optical fiber on the bottom side of the flex tape assembly 25. In fig. 8B, the seventh pattern 47 spans the entire width of the flex tape assembly 25.

In one embodiment, the first bond length b41 of the first bond region 30 may be substantially equal to the seventh bond length b47 of the second bond region 35. In other embodiments, the first bonding length b41 of the first bonding region 30 may be different from the seventh bonding length b47 of the second bonding region 35. Additionally, other embodiments may include other alternative irregular zig-zag patterns that describe the application of the plurality of second bonding regions 35.

Alternatively, as shown in fig. 8C, in other embodiments, the pattern of the plurality of second bonding areas 35 may have a smaller amplitude than that shown in fig. 8B. Thus, the eighth pattern 48 covers only a portion of the width of the flexible tape assembly 25. As shown, in one embodiment, the eighth bonded length b48 may be greater than the first bonded length b 41.

As shown in fig. 8B to 8C, the seventh and eighth patterns 47 and 48 do not have a proper waveform shape or a repeated triangular shape. Thus, in various embodiments, the second bonding regions 35 may be applied intermittently in varying amplitudes, pitches, and phases through other irregular patterns.

Fig. 8D illustrates another alternative embodiment of the present application wherein second bonded areas 35 are applied intermittently to second side 22 of flex tape assembly 25, forming an undulating ninth pattern 49. As shown, the ninth pattern 49 has a constant phase difference with respect to the first pattern 41 located at the first side 21. In the embodiment shown, the duty cycle of the ninth pattern 49 is 50%, but other values are possible in other embodiments.

Fig. 8E illustrates another alternative embodiment of the present application wherein second bonded areas 35 are applied intermittently to second side 22 of flex band assembly 25, forming a square wave. In various embodiments, the pattern formed by the second bonding areas 35 may include any type of wave, such as a square wave, a sine wave, a cosine wave, a triangular wave, and the like. For illustration, a square wave is used in fig. 8E. The second bonding areas 35 are configured at a 50% duty cycle to show the alternation between the intersection areas.

Fig. 9A to 9C illustrate the application of embodiments of the present application in forming an optical cable. While any type of fiber optic cable may use a unitized flexible tape, use of one shown in fig. 9A-9C is provided. Thus, FIG. 9A shows a folded unitized flexible tape, while FIG. 9B shows a cross-sectional view of a buffer tube formed using a plurality of flexible tape assemblies, and FIG. 9C shows a cross-sectional view of an optical cable including a plurality of buffer tubes of FIG. 8B.

Referring to fig. 9A, as explained in the above various embodiments, a plurality of optical fibers are arranged in parallel to each other and connected at the first and second bonding regions 30 and 35. As previously discussed, the first and second bonding areas 30, 35 are intermittently disposed across the flexible ribbon to selectively leave a large surface of the cable free of bonding material. As a result, the plurality of optical fibers maintain a large degree of freedom and can be effectively folded or randomly positioned when the ribbon is subjected to external stress.

In various embodiments, the plurality of optical fibers can be folded into a densely packed configuration. In one or more embodiments, the folded optical fiber can have a non-circular or irregular shape. In contrast, the encapsulated tapes cannot be folded efficiently because of their excessive rigidity.

FIG. 9B shows a buffer tube including a plurality of flexible tape assemblies according to an embodiment of the present application. In one embodiment, the buffer tube may be a deformable buffer tube that has been deformed during formation of the fiber optic cable. In other embodiments, the buffer tube may be a non-deformable buffer tube that maintains a circular shape with the optical cable.

The flexible band assembly 25 includes two or more flexible bands formed as described in the various embodiments above. The flexible tape assembly 25 is enclosed by a buffer tube jacket 110. In one or more embodiments, the buffer tube jacket 110 comprises polypropylene, porous polypropylene, polyethylene, nylon, or other materials.

Additionally, the flexible strip assemblies 25 may be dispersed within the gel 105, the gel 105 allowing the flexible strip assemblies 25 to move about relative to each other. In addition, the thickness of the buffer tube jacket 110 is maintained to give flexibility to the tape.

The buffer tube may be subjected to compressive stress during formation of the fiber optic cable. Due to the temperature dependent reduction in modulus during jacketing, the buffer tube may exhibit increased deformation under equivalent stress. As a result, the flexible tape assembly 25 within the buffer tube 100 may reconfigure shape/configuration to compensate for or minimize this compressive stress.

The reconfiguration of the flex tape assembly 25 within the cable does not cause twisting or bending of the optical fibers. Accordingly, embodiments of the present application achieve improved packing density without sacrificing the mechanical or optical properties of the fiber optic cable.

The collapsible flex tape assembly 25 extends longitudinally along each buffer tube 100 and allows each flex tape (such as first flex tape 50 and second flex tape 60) to adopt a random configuration. The attendant twisting of the plurality of buffer tubes 100 (if any) when forming the cable is sufficient to average the strain across the optical fibers and meet the mechanical and optical standards of the fiber optic cable.

In fig. 9B, although only two flexible tape assemblies 25 are shown within buffer tube 100, in various embodiments, buffer tube 100 may include a greater number or even a lesser number of flexible tape assemblies 25. For example, in one embodiment, buffer tube 100 may include twelve or twenty-four flexible tape assemblies 25. Additionally, each flex band assembly 25 may include any suitable number of flex bands (such as first flex band 50 and second flex band 60). Each flexible strip may similarly have any number of optical fibers. In various embodiments, the diameter of the optical fiber may range from 100 μm to 300 μm. For example, in one illustration, each flexible ribbon may include twelve optical fibers. Thus, in this example, buffer tube 100 includes 288 or 576 optical fibers.

Fig. 9C illustrates a cross-sectional view of a fiber optic cable implementing an embodiment of the present application.

Embodiments of the present application may be implemented in many types of fiber optic cables. However, for purposes of illustration, a particular fiber optic cable is shown. Referring to fig. 9C, the cable includes a rigid central strength member 120. An upper jacket 130 surrounds the central strength member 120. The outer cover 175 of the cable may include multiple layers, such as a water-blocking layer 165, an optional outer strength member 160 (which may include a steel armor), and an outer jacket 170.

The optical cable also includes a buffer tube 100, the buffer tube 100 including a plurality of flexible tape assemblies 25, the flexible tape assemblies 25 including a plurality of optical fibers. As previously described, the flexible tape assembly 25 is disposed into the buffer tube 100. Buffer tube 100 may have a rigid circular shape or may be a deformable buffer tube that conforms to the shape of the configuration of flexible tape assembly 25. The spaces 150 between buffer tubes 100 may be empty or optionally filled with a suitable filler material.

In various embodiments, the fiber optic cable may be designed to be compatible with one or more standards.

Fig. 10A-10E illustrate a unitized flexible belt at various stages of manufacture, featuring a method with a moving belt or moving belt assembly, according to embodiments of the present application.

FIG. 10A shows a schematic system diagram illustrating the formation of a flexible ribbon from a plurality of optical fibers according to an embodiment of the present invention.

A plurality of optical fibers 2, such as individual fibers of the first set of optical fibers 51-58, are paid out from a spool and fed into the first mold 12, and the longitudinal fiber assembly 25 is positioned such that the plurality of optical fibers 2 are parallel and adjacent to each other. The direction of the arrow indicates the movement of the optical fiber 2 during the process.

The first dispensing device 226 applies a bonding material (such as a UV curable resin) to the surface of the fiber optic assembly 25 at the first side 21. The bonding material may also be a thermoplastic material such that the first distribution device 226 applies a strand of thermoplastic material to a surface of the fiber optic assembly 25. For example, the thermoplastic material may be heated above its softening point and formed into a wire, and the softened thermoplastic wire may be applied to the surface of the optical fiber assembly 25. After cooling, the applied thermoplastic strands form the first bond regions described in the various embodiments.

When a curing process is desired, the fiber optic assembly 25 with the applied bonding material then passes through the first curing station 16, after which the flexible tape assembly 50 is picked up on a take-up reel 215.

FIG. 10B shows an enlarged view of a plurality of flexible straps in the method described above in FIG. 10A.

Referring to fig. 10B, for example, a plurality of flexible strips (such as first flexible strip 50) are formed in sequence. As shown, the first set of optical fibers 51-58 are paid out from a spool and positioned parallel to each other on the first moving carrier 212. The first mobile carrier 212 may comprise a conveyor belt or any other suitable structure. Alternatively, the first set of optical fibers 51-58 may be freely suspended while supported by rollers, which may also provide for translational movement of the optical fibers along their length.

Each of the first set of optical fibers 51-58 is configured parallel to one another during this process, e.g., extending into the page of FIG. 10B. The first set of optical fibers 51-58 has a first side 21 facing away from the first moving carrier 212.

The first moving carrier 212, with parallel optical fibers 51-58 disposed on top, passes through a first distribution device 226. The first moving nozzle 237 is positioned above the first set of optical fibers 51-58. Matrix material 225 is applied to the cross-connect between the optical fibers from the first dispensing nozzle 237. The matrix material 225 fills the gaps between adjacent optical fibers and forms the first bonding regions 30 after curing.

In various embodiments, the matrix material 225 may include resins, acrylic-based adhesives (including UV curable acrylate materials), other polymeric materials, thermoplastic materials.

The first moving nozzle 237 may oscillate in a direction transverse to the direction of the longitudinally passing optical fiber or ribbon (or may be stationary when dispensing a drop of material between two flexible ribbons). In other words, the first moving nozzle 237 may be along the longitudinal direction D in fig. 10B₂Vibrate or vibrate into the plane of fig. 10A.

Alternatively, the matrix material 225 is dispensed shortly before the first moving nozzle 237 within the first dispensing device 226 shuts off the matrix material 225. For example, the matrix material 225 is released while the first set of optical fibers 51-58 are moved in a longitudinal direction, where the longitudinal direction is out of the plane of the page in FIG. 10B. Subsequently, the first moving nozzle 237 is closed so that the matrix material 225 is not released.

Then, the first moving nozzle 237 is along the direction D₂Moves relative to the first moving carrier 212, transverse to the longitudinal direction along the optical fibers, to the next cross-connect of the first set of optical fibers 51-58. Further, the translation of the first set of optical fibers 51-58 may continue with the first motive nozzle 237 closed. Subsequently, the first moving nozzle 237 is opened again, and the matrix material 225 is released at the cross-connections between adjacent optical fibers while moving the first group of optical fibers 51-58 in the longitudinal direction. Thus, the first moving nozzle 237 may step-wise pass the first set of optical fibers 51-58 until the matrix material 225 used to form the predetermined pattern of first bonding regions 30 is released.

The matrix material 225 is then cured to form the first flexible strip 50, the first flexible strip 50 including, for example, the first bonded areas 30 having the first pattern 41. The curing process may include passing through the first curing station 16, room temperature curing for a predetermined time, higher temperature curing (e.g., 50 ℃ to 300 ℃), exposure to UV light, and the like.

The first distribution device 226 may be configured to apply the matrix material 225 to the second set of optical fibers 61-68 after the first flexible strip 50 is formed. For example, the first flexible ribbon 50 may be removed from the first moving carrier 212 by a take-up reel and the second set of optical fibers 61-68 may be deployed to the first moving carrier 212. The step of releasing the matrix material 225 may be repeated as described above while forming the first flexible strip 50 (see also the schematic arrow showing this step).

Thus, a plurality of flexible strips, such as first flexible strip 50 (and subsequently second flexible strip 60) is formed.

Fig. 10C-10E illustrate a unitized flexible belt during formation according to an embodiment of the present application. Fig. 10C (similar to fig. 10A) illustrates a flex tape assembly formed from a plurality of flex tapes, according to an embodiment of the invention. Fig. 10D shows a cross-sectional view of the plurality of flexible strips during formation of the second bonding regions at the opposite bottom side, and fig. 10E shows a top view of the plurality of flexible strips during formation of the second bonding regions along the predetermined pattern at the bottom side.

A plurality of flexible ribbons (such as first flexible ribbon 50 and second flexible ribbon 60) designed as part of a unitized flexible ribbon are paid out from a reel, enter second mold 224, and are optionally disposed on second moving carrier 232. In particular, the first flexible strip 50 and the second flexible strip 60 are configured such that a second side 22, opposite to the first side 21 comprising the first bonding region 30, faces away from the second movement carrier 232. Alternatively, the first flexible strip 50 and the second flexible strip 60 may be freely suspended between the rollers, which may also provide translational movement along the length of the flexible strips (direction of the arrows).

The second dispensing device 227 may be the same tool as the first dispensing device 226 previously used in one or more embodiments. Alternatively, the second dispensing device 227 for forming the unitized tape may be different from the first dispensing device 226. Similarly, the second mobile carrier 232 may be the same as or different from the first mobile carrier 212 in various embodiments. Similarly, the substrate material 225 dispensed from the first dispensing device 226 may be different from the substrate material 225 dispensed from the second dispensing device 227.

In embodiments such as those illustrated using fig. 1A-1C, 2A-2B, or 3A-3C, a continuous flow of substrate material 225 from the second dispensing device 227 is maintained as the second moving carrier 232 moves along a longitudinal direction parallel to the length of the first and second flexible strips 50, 60.

Even in other embodiments that use intermittent bonding areas (such as the illustration of fig. 4B), the matrix material 225 may still be dispensed continuously. For example, in one illustration, a continuous sinusoidal line of matrix material 225 is applied to the surface of the first flexible strip 50 and/or the second flexible strip 60. By selecting an appropriate viscosity and surface tension, the bonding material, although continuously applied, forms discrete bonds between successive fibers. Advantageously, the continuous application of the matrix material 225 to form discrete or intermittent bonded regions is less complex and therefore less expensive.

However, in other embodiments using intermittent bond areas (such as the illustration of fig. 4B), the substrate material 225 is dispensed shortly before the second moving nozzle 239 in the second dispensing device 227 turns off the substrate material 225. For example, the matrix material 225 is released while the second moving carrier 232 is moving along a longitudinal direction parallel to the length of the optical fibers, which is out of the plane of the page in fig. 10D. Subsequently, the second moving nozzle 239 is closed so that the matrix material 225 is not applied. Second moving nozzle 239 in transverse direction D₂Moves relative to the second moving carrier 232 to move to the next cross-connect of optical fibers. Furthermore, another translation of the second moving carrier 232 in the longitudinal direction may also be performed when the nozzle is closed. Subsequently, another translation of the second mobile carrier 232 in the longitudinal direction can also take place with the nozzle closed. Subsequently, second mobile carrier 232 is translated in longitudinal direction and second mobile nozzle 239 is translated in transverse direction D₂After the upper translation, the second moving nozzle 239 is opened again and the matrix material 225 is released at the cross-connection between adjacent optical fibers while moving the second moving carrier 232 in the longitudinal direction.Thus, the second moving nozzle 239 may step-by-step pass through the first flexible strip 50 and the second flexible strip 60 until the matrix material 225 for forming the predetermined pattern of the second bonding areas 35 is released. All translations may be performed simultaneously or simultaneously.

As previously described, the matrix material 225 is subsequently cured, such as in the second curing station 236, to form the flexible tape assembly 25. The flexible tape assembly 25 is then picked up from the second mobile carrier 232 by the pick-up reel 222.

According to the previously described embodiments, the second bonding regions 35 may be continuous or intermittent and may comprise different patterns, such as wavy or linear patterns having various regular or irregular wavelengths, amplitudes and phases that may be controlled by the relative positions of the second moving nozzle 239 and the second moving carrier 232 during application.

According to the embodiment previously illustrated in fig. 10A to 10E, the manufacturing process is carried out with a moving belt or belt assembly which is passed through a first dispensing device, wherein the nozzle is moved in a direction transverse to the direction of the longitudinally passed belt. In other embodiments, the manufacture of the unitized flexible tape is performed using a stationary belt or belt assembly and a dispenser that travels the length of the belt. Fig. 11A and 11B illustrate a unitized flexible belt at various stages of manufacture according to an embodiment of the present application having a stationary belt or belt assembly.

Fig. 11A shows a plurality of flexible straps during the formation of a first bonded area at the top side.

Similar to the previous embodiment, matrix material 225 is applied to the cross-connects between the optical fibers from the first distribution tool 220. The first dispensing tool 220 may be similar to the first dispensing device 226 previously described. Unlike the previous embodiment, the optical fiber is positioned in a stationary position with the nozzle moving.

The matrix material 225 is dispensed shortly before the matrix material 225 is turned off by the nozzle 235 in the first dispensing tool 220. For example, the matrix material 225 is released while the first dispensing tool 220 is moved relative to the first carrier 210 along a first direction parallel to the length of the optical fibers, the first direction being into the plane of the page of fig. 11A. Subsequently, the matrix material 225 is turned off so that the matrix material 225 is not released.

Then, the first distribution tool 220 is along the transverse direction D₂Moves relative to the first carrier 210 to move to the next cross-connect of the first set of optical fibers 51-58. Further, another translation in the first direction may also be performed with the nozzle 235 closed. Subsequently, after translation in the first and second directions, the nozzle is opened again and the matrix material 225 is released at the cross-connections between adjacent optical fibers while the first dispensing tool 220 is moved in the first direction relative to the first carrier 210. Thus, the first dispensing tool 220 may step-wise pass through the first set of optical fibers 51-58 until the matrix material 225 used to form the predetermined pattern of first bonding regions 30 is released.

The matrix material 225 is then cured to form the first flexible band 50. Once the first distribution tool 220 traverses all of the optical fibers of the first set of optical fibers 51-58, a curing process may be provided to form the first bonding areas 30 having, for example, the first pattern 41 described above. Similarly, the step of releasing the matrix material 225 (see also the schematic arrow showing this step) may be repeated as described above while forming the first flexible strip 50 to form a second flexible strip.

Thus, a plurality of bands, such as first flexible band 50 (and second flexible band 60) are formed.

FIG. 11B illustrates a cross-sectional view of a plurality of flexible straps during formation of a second bonded area on an opposite bottom side.

Unlike the previous embodiment of fig. 10C-10E, the flexible band is positioned in a rest position while the dispensing nozzle is moving. Thus, a plurality of flexible belts designed as part of a unitized flexible belt, such as first flexible belt 50 and second flexible belt 60, are configured to the second carrier 230 or held in a stationary position between the rollers. In particular, the first flexible strip 50 and the second flexible strip 60 are configured such that a second side 22, opposite to the first side 21 comprising the first bonding region 30, faces away from the second carrier 230.

The second dispensing tool 221, which may be similar to the second dispensing device 227, may be the same tool as the first dispensing tool 220 previously used in one or more embodiments. Alternatively, the second dispensing tool 221 for forming the unitized tape may be different from the first dispensing tool 220. Similarly, in various embodiments, the second carrier 230 may be the same as or different from the first carrier 210. Similarly, the substrate material 225 dispensed from the first dispensing tool 220 may be different from the substrate material 225 dispensed from the second dispensing tool 221.

In embodiments such as those illustrated using fig. 1A-1C, 2A-2B, or 3A-3C, a continuous flow of substrate material 225 is maintained as the second dispensing tool 221 moves relative to the second carrier 230 along a first direction parallel to the length of the first and second flexible strips 50, 60.

However, in other embodiments using intermittent bond areas (such as the illustration of fig. 4B), the substrate material 225 is dispensed for a short period of time before the nozzle 235 in the second dispensing tool 221 shuts off the substrate material 225. For example, in a first direction D parallel to the length of the optical fiber at the second dispensing tool 221₁While moving relative to the second carrier 230, wherein the first direction D is₁Into the plane of the page of fig. 10B. Subsequently, the nozzle 235 is closed so that the matrix material 225 is not applied. The second dispensing tool 221 is along a second direction D₂Moves relative to the second carrier 230 to move to the next cross-connect of optical fibers. Furthermore, it is also possible to proceed in the first direction D while the nozzle is closed₁Another translation of (a). Subsequently, after translation in the first and second directions, the nozzle is opened again and the matrix material 225 is released at the cross-connections between adjacent optical fibers while moving the second dispensing tool 221 relative to the second carrier 230 in the first direction. Thus, the second dispensing tool 221 may step-by-step pass through the first flexible strip 50 and the second flexible strip 60 until the substrate material 225 used to form the predetermined pattern of second bond regions 35 is released.

The matrix material 225 is then cured, for example as previously described, to form the flex tape assembly 25.

According to the previously described embodiments, the second bonding areas 35 may be continuous or intermittent and may comprise different patterns, such as wavy or linear patterns having various regular or irregular wavelengths, amplitudes and phases that may be controlled by the relative positions of the second dispensing tool 221 and the second carrier 230 during application.

Example embodiments of the present invention are summarized herein. Other embodiments are also understood from the entire specification and claims presented herein.