Fiber optic cables having coupling and methods therefor

Abstract

A fiber optic cable including at least one optical fiber disposed within a cavity of a cable jacket and methods for manufacturing the same are disclosed. The cavity has a first cavity cross-sectional area and a second cavity cross-sectional area located at different longitudinal locations along the cable, where the first cavity cross-sectional area is greater than the second cavity cross-sectional area. The region of the second cavity cross-sectional area of the cable provides and/or increases the coupling level of the at least one optical fiber to the cable jacket. In further embodiments, the fiber optic cable is a dry cable having one or more dry insert within the cavity for cushioning and/or optionally providing water-blocking for the cable.

1 . A fiber optic cable comprising;
 at least one optical fiber; and   a cable jacket, the cable jacket having at least one cavity, wherein the at least one optical fiber is disposed within the at least one cavity, the at least one cavity having a first cavity cross-sectional area (CA 1 ) and a second cavity crops-sectional area (CA 2 ) located at different longitudinal locations along the cable, wherein the first cavity cross-sectional area is greater than the second cavity cross-sectional area.   
   
   
       2 . The fiber optic cable of  claim 1 , the cavity having a cavity cross-sectional ratio being defined as the second cavity cross-sectional area divided by the first cavity cross-sectional area, wherein the cavity cross-sectional ratio (CA 2 /CA 1 ) is between about 50 % and about 90 %. 
   
   
       3 . The fiber optic cable of  claim 1 , the at least one optical fiber having a predetermined level of coupling to the cable jacket wherein the predetermined level of coupling is about 0.1625 Newtons or more per optical fiber for a thirty meter length of fiber optic cable. 
   
   
       4 . The fiber optic cable of  claim 1 , further comprising one or more water blocking elements disposed in the at least one cavity selected from the group of a water blocking powder, a water blocking yarn, a water-blocking thread, a water blocking tape, and a water blocking gel. 
   
   
       5 . The fiber optic cable of  claim 1 , further comprising one or more dry inserts disposed in the at least one cavity. 
   
   
       6 . (canceled) 
   
   
       7 . The fiber optic cable of  claim 1 , further comprising further comprising a first strength element and a second strength element attached to the cable jacket on opposite sides of the at least one cavity. 
   
   
       8 . (canceled) 
   
   
       9 . The fiber optic cable of  claim 1 , the fiber optic cable having a flame-retardant characteristic. 
   
   
       10 . (canceled) 
   
   
       11 . The fiber optic cable of  claim 1 , wherein the fiber optic cable is a portion of a fiber optic cable assembly. 
   
   
       12 . A fiber optic cable comprising:
 at least one optical fiber;   at least one dry inserts; and   a cable jacket, the cable jacket having at least one cavity, wherein the at least one optical fiber and the at least one dry insert are disposed within the at least one cavity, the cavity having a first cavity cross-sectional area (CA 1 ) and a second cavity cross-sectional area (CA 2 ) located at different longitudinal locations along the cable, wherein the first cavity cross-sectional area is greater than the second cavity cross-sectional area.   
   
   
       13 . The fiber optic cable of  claim 12 , the cavity having a cavity cross-sectional ratio being defined as the second cavity cross-sectional area divided by the first cavity cross-sectional area, wherein the cavity cross-sectional ratio (CA 2 /CA 1 ) is between about 50 % and about 90 %. 
   
   
       14 . The fiber optic cable of  claim 12 , the at least one optical fiber having a predetermined level of coupling to the cable jacket wherein the predetermined level of coupling is about 0.1625 Newtons or more per optical fiber for a thirty meter length of fiber optic cable. 
   
   
       15 . The fiber optic cable of  claim 12 , further comprising one or more water blocking elements disposed in the at least one cavity selected from the group of a water blocking powder, a water-blocking yarn, a water blocking thread, a water blocking tape, and a water blocking gel. 
   
   
       16 . The fiber optic cable of  claim 12 , the at least one dry insert having a compressible layer and a water-swellable layer that are attached together. 
   
   
       17 . (canceled) 
   
   
       18 . The fiber optic cable of  claim 12 , further comprising a first strength element and a second strength element attached to the cable jacket on opposite sides of the at least one cavity. 
   
   
       19 . (canceled) 
   
   
       20 . The fiber optic cable of  claim 12 , the fiber optic cable having a flame-retardant characteristic. 
   
   
       21 . (canceled) 
   
   
       22 . The fiber optic cable of  claim 12 , wherein the fiber optic cable is a portion of a fiber optic cable assembly. 
   
   
       23 . A method for manufacturing a fiber optic cable comprising at least one optical fiber disposed in at least one cavity of a cable jacket comprising the steps of:
 providing at least one optical fiber;   applying a cable jacket about the at least one optical fiber, the cable jacket having a cavity, wherein the step of applying the cable jacket includes changing a cavity cross-sectional area between a first location and a second location along a length of the cable jacket for improving coupling of the at least one optical fiber.   
   
   
       24 . The method of  claim 23 , the step of changing of the cavity cross-sectional area being selected from the group of applying a cable jacket having a wall thickness that varies the cavity cross-sectional area at one or more locations along the cable jacket or deforming the cable jacket while is it still molten. 
   
   
       25 . The method of  claim 23 , wherein the at least one cavity has a first cavity cross-sectional area (CA 1 ) and a second cavity cross-sectional area (CA 2 ) located at different longitudinal locations along the cable and a cavity cross-sectional ratio is defined as the second cavity cross-sectional area divided by the first cavity cross-sectional area, wherein the cavity cross-sectional ratio (CA 2 /CA 1 ) is between about 50 % and about 90 %. 
   
   
       26 . The method of  claim 23 , wherein the at least one optical fiber has a predetermined level of coupling to the cable jacket wherein the predetermined level of coupling is about 0.1625 Newtons or more per optical fiber for a thirty meter length of fiber optic cable. 
   
   
       27 . The method of  claim 23  further comprising the step of providing one or more water blocking elements for inhibiting the migration of water along the fiber optic cable. 
   
   
       28 . The method of  claim 23 , further comprising the step of applying one or more dry inserts that are disposed within the at least one cavity. 
   
   
       29 . (canceled) 
   
   
       30 . The method of  claim 23 , further comprising the step of applying a first strength element and a second strength element, wherein the first strength element and the second strength element are disposed on opposite sides of the at least one cavity. 
   
   
       31 . (canceled) 
   
   
       32 . The method of  claim 23 , the step of applying the cable jacket including using a polymer having a flame-retardant characteristic. 
   
   
       33 . The method of  claim 23 , further comprising the step of applying an armor component.