US 6,557,249 B1 · Optical fiber deployment system and cable

Abstract

The present invention is a strengthened fiber optic cable and the process for inserting the strengthened cable into a duct. The invention consists of pre-coating a fiber optic waveguide with an ultra violet (UV)/visible light curable resin such that the resin buffers the fiber optic waveguide. The pre-coated fiber optic waveguide is then cured in an UV/visible light oven at a temperature at ambient or above. An UV/visible light curable resin is pre-heated to a selected temperature and the buffered fiber optic waveguide and the at least one reinforcing fiber are transported through a binding resin bath, the fiber optic waveguide maintaining linear alignment throughout the bath as at least one reinforcing fiber is disposed about the fiber optic waveguide. The resin coated fiber optic waveguide and the least one reinforcing fiber are then cured in an UV/visible light curing station so as to form a fiber optic cable. The fiber optic cable is then transported to and insertion means which imparts sufficient translational force to the cable to impel the cable to a selected location in a duct.

Claims96

Dependent claims

A process for inserting a fiber optic cable into a duct, the process including:

(a) strengthening a fiber optic waveguide to form a semi-flexible cable;
and
(b) retrievably impelling the fiber optic cable into the duct.

A process for inserting a fiber optic cable into a duct, the process including:

(a) pre-heating a binding resin bath, the binding resin bath for coating a fiber optic waveguide and at least one strengthening fiber with an UV/visible light curable resin, the resin for binding the fiber optic waveguide and the at least one reinforcing fiber, the resin bath pre-heated to a selected temperature prior to transporting the fiber optic waveguide and the at least one reinforcing fiber through the binding resin bath, the selected temperature from about 60° C. to about 100° C.;
(b) linearly aligning the fiber optic waveguide with the binding resin;
(c) disposing at least one reinforcing fiber about the fiber optic waveguide;
(d) transporting the fiber optic waveguide and the at least one reinforcing fiber through the binding resin bath, the step of transporting the fiber optic waveguide and the at least one reinforcing fiber through the binding resin bath including the step of transporting the fiber optic waveguide and the at least one reinforcing fiber through a plurality of plates defining orifices for receiving the fiber optic waveguide and the at least one reinforcing fiber, the plurality of plates providing a guide path through the binding resin bath for the fiber optic waveguide and the at least one reinforcing fiber;
(e) simultaneously coating the fiber optic waveguide and the at least one reinforcing fiber with the binding resin while temperature of the binding resin is maintained in the selected range from about 60° C. to about 100° C.;
(f) curing the binding resin-coated fiber optic waveguide and the at least one reinforcing fiber in an UV/visible light curing station so as to form a fiber optic cable, whereby the binding resin-coated fiber optic waveguide and the at least one reinforcing fiber are transported through UV/visible light curing station at a constant speed of about 5 up to about 300 feet per minute, the curing station having a power rating of greater than 200 watts per inch, and having a length of about 1 inch to about 96 inches;
(g) transporting the fiber optic cable to an insertion means, the insertion means for imparting sufficient translational force to the cable to impel the cable to a selected location in the duct, the insertion means including an inlet guide, the inlet guide for providing a flow path for providing a guide path for the fiber optic cable, the inlet in linear alignment with a feed wheel, having a known circumference, a pressure roller, the pressure roller in radial alignment with the feed wheel, the feed wheel and the pressure roller forming an aperture for receipt of the fiber optic cable, the pressure roller for biasing the fiber optic cable against the feed wheel, a power source for imparting rotational movement to the feed wheel, an insertion guide, the insertion guide in linear alignment with the inlet guide, the insertion guide positioned to provide a guide path for the fiber optic cable to the duct the motive force includes a feed wheel;
(h) guiding the fiber optic cable through the inlet guide, the aperture between the feed wheel and the pressure roller, through the outlet guide, and into the duct, and whereby the step of applying the translational force to the fiber optic cable includes:
(i) biasing the pressure roller against the fiber optic cable;
and
(ii) applying rotational movement to a feed wheel, thereby impelling the fiber optic cable into the duct.

8 more elements

A process for making a strengthened cable, the process including:

(a) receiving a fiber optic waveguide from a source;
(b) pre-coating the fiber optic waveguide with an UV/visible light curable silicone resin, the resin selected to buffer the fiber optic waveguide at a temperature of about ambient or above;
(c) curing the pre-coated fiber optic waveguide;
(d) pre-heating a binding resin bath, the binding resin bath for coating a fiber optic waveguide and at least one strengthening fiber with an UV/visible light curable resin, the resin for binding the fiber optic waveguide and the at least one reinforcing fiber, the resin bath pre-heated to a selected temperature prior to transporting the fiber optic waveguide and the at least one reinforcing fiber through the binding resin bath, the selected temperature from about 60° C. to about 100° C., and wherein the binding resin is selected such that it imparts a strain elongation at failure greater that 2% to the fiber optic cable;
(e) linearly aligning the fiber optic waveguide with the binding resin;
(f) disposing at least one reinforcing fiber about the fiber optic waveguide;
(g) linearly transporting, by means of feed rolls and bobbins in a substantially linear alignment to the binding resin bath, the fiber optic waveguide and the at least one reinforcing fiber through the binding resin bath, the step of transporting the fiber optic waveguide and the at least one reinforcing fiber through the binding resin bath including the step of transporting the fiber optic waveguide and the at least one reinforcing fiber through a plurality of plates defining orifices for receiving the fiber optic waveguide and the at least one reinforcing fiber, the plurality of plates providing a guide path through the binding resin bath for the fiber optic waveguide and the at least one reinforcing fiber;
(h) simultaneously coating the fiber optic waveguide and the at least one reinforcing fiber with the binding resin while temperature of the binding resin is maintained in the selected range from about 60° C. to about 100° C., the binding resin consisting of a formulation of heterocyclic high temperature (meth)acrylate resins;
(i) curing the binding resin-coated fiber optic waveguide and the at least one reinforcing fiber in an UV curing station so as to form a fiber optic cable, whereby the binding resin-coated fiber optic waveguide and the at least one reinforcing fiber are transported through UV curing station at a constant speed of about 5 up to about 300 feet per minute, the curing station having a power rating of greater than 200 watts per inch, and having a length of about 1 inch to about 96 inches;
and
(j) collecting the fiber optic cable.

8 more elements

Dependencies are inferred from the claim text.

Optical fiber deployment system and cable

Life of this patent

Optical fiber deployment system and cable

Life of this patent

Abstract

Claims96