Method for drop cable having an oval cavity

Abstract

A method of forming a low-cost drop cable (10) is disclosed. The method includes providing a protective cover material (352) having an extrusion temperature of 140° C.≦TE≦160° C. The protective cover material is extruded through a die (420) having a single aperture (424) that defines the cable's elongate cross-sectional shape. The extrusion process involves covering first and second strength members (30) on either side of at least one optical fiber (50). The combination of the low temperature of the extrudable protective cover material and the elongate shape of the single die aperture cause the formation of an oval cavity (20) within the extruded protective cover material. The oval cavity has major and central axes (A1, AC) and surrounds the at least one optical fiber. The strength members lie along the cavity major axis. Tensioning the strength members during extrusion and then releasing the tension causes the drop cable length to be reduced. This gives rise to an excess fiber length, which adopts a serpentine configuration substantially in a plane (PF) defined by the major and central axes (A1, A2) of the oval cavity.

Dependencies are inferred from the claim text.