Fiber optic cable having a dry insert and methods of making the same

Abstract

A fiber optic cable and a method of making the same include at least one optical waveguide, at least one dry insert and a cable jacket. The at least one optical waveguide and at least one dry insert are at least partially disposed within a cavity of the cable jacket. In one embodiment, the cable includes a first dry insert and a second dry insert disposed within the cavity so that the at least one optical waveguide is disposed between the first dry insert and the second dry insert, thereby providing a dry cable core.

1 - 26 . (canceled) 
   
   
       27 . A fiber optic cable comprising:
 a plurality of fiber optic ribbons, the plurality of fiber optic ribbons having an excess ribbon length (ERL), the ERL being greater than 1.2%;   a cable jacket having a cavity, wherein the plurality of fiber optic ribbons are at least partially disposed within the cavity;   at least one dry insert, the at least one dry insert being disposed within the cavity and contacting the at least one of the plurality of fiber optic ribbons for coupling the plurality of fiber optic ribbons to the cable jacket; and   at least two strength members that are disposed on opposite sides of the cavity.   
   
   
       28 . The fiber optic cable of  claim 27 , the ERL being about 1.5% or greater. 
   
   
       29 . The fiber optic cable of  claim 27 , at least one of the optical fiber ribbons having a plurality of bend resistant optical fibers. 
   
   
       30 . The fiber optic cable of  claim 27 , the at least one dry insert comprising a first and a second dry insert having a combined uncompressed height, the combined uncompressed height being about 40% or more of a cavity height of the cavity. 
   
   
       31 . The fiber optic cable of  claim 27 , wherein the plurality of optical fiber ribbons having a total of 60 optical fibers or more. 
   
   
       32 . The fiber optic cable of  claim 27 , the fiber optic cable includes four or more optical fiber ribbons. 
   
   
       33 . The fiber optic cable of  claim 27 , at least one of the plurality of fiber optic ribbons having twenty-four optical fibers or more. 
   
   
       34 . The fiber optic cable of  claim 27 , wherein the ribbon stack has a fiber height that is about 25% or more of a cavity height. 
   
   
       35 . The fiber optic cable of  claim 27 , wherein the ribbon stack has a fiber height that is about 35% or more of a cavity height. 
   
   
       36 . The fiber optic cable of  claim 27 , the at least one dry insert having a compressible layer. 
   
   
       37 . The fiber optic cable of  claim 27 , the at least one dry insert having a water-swellable layer. 
   
   
       38 . The fiber optic cable of  claim 27 , the at least one dry insert including a foam tape. 
   
   
       39 . The fiber optic cable of  claim 27 , the at least one dry insert includes a water-swellable layer, wherein the water-swellable layer faces outward towards the cavity wall. 
   
   
       40 . The fiber optic cable of  claim 27 , the at least one dry insert including a plurality of microspheres. 
   
   
       41 . The fiber optic cable of  claim 27 , the at least one dry insert including a dimensional fabric. 
   
   
       42 . The fiber optic cable of  claim 27 , the at least one dry insert including a felt substance. 
   
   
       43 . The fiber optic cable of  claim 27 , the at least one dry insert comprising a matrix material and a plurality of filaments. 
   
   
       44 . The fiber optic cable of  claim 27 , wherein each strength member has a strength member dimension, wherein the cavity has a cavity height and the cavity height is larger than the strength member dimension. 
   
   
       45 . The fiber optic cable of  claim 27 , a minor dimension of the fiber optic cable being about 15 millimeters or less and a major dimension of the fiber optic cable being about 25 millimeters or less. 
   
   
       46 . The fiber optic cable of  claim 27 , further comprising a component having a water-swellable characteristic or a water-blocking characteristic. 
   
   
       47 . The fiber optic cable of  claim 27 , the plurality of optical fiber ribbons being non-stranded within the cavity. 
   
   
       48 . The fiber optic cable of  claim 27 , the cavity having a generally rectangular shape. 
   
   
       49 . The fiber optic cable of  claim 27 , one of the plurality of ribbons contacting at least a portion of the at least one dry insert. 
   
   
       50 . The fiber optic cable of  claim 27 , further comprising at least one armor layer for protecting the fiber optic cable. 
   
   
       51 . The fiber optic cable of  claim 27 , further comprising a first dry insert and a second dry insert and the plurality of optical fiber ribbons being disposed between the first dry insert and the second dry insert. 
   
   
       52 . The fiber optic cable of  claim 27 , wherein the cable jacket is formed from two different materials. 
   
   
       53 .- 92 . (canceled)