Splice protector for fiber optic ribbons

Abstract

A fiber optic cable assembly includes first and second fiber optic ribbons and a splice protector. The ribbons are spliced together such that the corresponding spliced fibers at the splice have a common lengthwise axis, widthwise axis orthogonal to the lengthwise axis, and thickness axis orthogonal to the lengthwise and widthwise axes. The splice protector supports the ribbons that are spliced to one another at the splice. The splice protector may include or even consist essentially of an adhesive that provides a flexible support for the splice. The splice protector may be at least half as flexible when cured over the splice as the first and second ribbons in bending about the widthwise axis.

What is claimed is: 
     
       1. A fiber optic assembly, comprising:
 first and second fiber optic ribbons, each comprising a plurality of optical fibers coupled in an arrangement where the optical fibers are aligned side-by-side with one another, wherein the optical fibers of the first ribbon are spliced with the optical fibers of the second ribbon such that the spliced ribbons at the splice have a common lengthwise axis, widthwise axis orthogonal to the lengthwise axis, and thickness axis orthogonal to the lengthwise and widthwise axes; and 
 a splice protector supporting the optical fibers of the first and second fiber optic ribbons that are spliced to one another at the splice, wherein the splice protector comprises an adhesive that provides a flexible support for the splice, wherein the splice protector and the splice are bendable around curved surfaces about the widthwise axis, and wherein the splice protector is at least half 60% as flexible when cured over the splice as the first and second ribbons in bending about the widthwise axis, and wherein the splice protector is at least 60% as flexible as the first and second ribbons in bending about the widthwise axis at the splice. 
 
     
     
       2. The fiber optic assembly of  claim 1 , wherein the splice protector has a low-profile, having a thickness in the thickness axis that is less than 1 mm thicker than either the first or second fiber optic ribbons in the thickness axis. 
     
     
       3. The fiber optic assembly of  claim 2 , wherein the splice protector has a narrow-profile, having a width in the width widthwise axis that is less that than 1 mm wider than either the first or second fiber optic ribbons in the width widthwise axis. 
     
     
       4. The fiber optic assembly of  claim 1 , wherein the splice protector is at least as flexible as the first and second ribbons in bending about the widthwise axis. 
     
     
       5. The fiber optic assembly of  claim 1 , wherein the splice protector does not include a substrate. 
     
     
       6. The fiber optic assembly of  claim 1 , wherein the splice protector consists of UV-curable adhesive. 
     
     
       7. A fiber optic assembly, comprising:
 first and second fiber optic ribbons, each comprising a plurality of optical fibers coupled in an arrangement where the optical fibers are aligned side-by-side with one another, wherein the optical fibers of the first ribbon are spliced with the optical fibers of the second ribbon such that the spliced ribbons at the splice have a common lengthwise axis, widthwise axis orthogonal to the lengthwise axis, and thickness axis orthogonal to the lengthwise and widthwise axes; and 
 a splice protector supporting the optical fibers of the first and second fiber optic ribbons that are spliced to one another at the splice, wherein the splice protector comprises an ultra-violet light (UV-) curable adhesive facilitating a controlled profile for the splice protector; 
 wherein the splice protector has a low-profile, having a thickness in the thickness axis that is less than 1 0.75 mm thicker than either the first or second fiber optic ribbons in the thickness axis; and 
 wherein the splice protector has a narrow-profile, having a width in the width widthwise axis that is less that than 1 mm wider than either the first or second fiber optic ribbons in the width widthwise axis, and wherein the thickness of the splice protector is less than 0.75 mm thicker than either the first or second fiber optic ribbons in the thickness axis; and 
 wherein the splice protector and the splice are bendable around curved surfaces about the widthwise axis. 
 
     
     
       8. The fiber optic assembly of  claim 7 , wherein the thickness of the splice protector is less than 0.5 mm thicker than either the first or second fiber optic ribbons in the thickness axis. 
     
     
       9. The fiber optic assembly of  claim 7 , wherein the width of the splice protector is less that than 0.75 mm wider than either the first or second fiber optic ribbons in the width widthwise axis. 
     
     
       10. The fiber optic assembly of  claim 7 , wherein the width of the splice protector is less that than 0.5 mm wider than either the first or second fiber optic ribbons in the width widthwise axis. 
     
     
       11. The fiber optic assembly of  claim 7 , wherein the splice protector does not include a substrate. 
     
     
       12. The fiber optic assembly of  claim 11 , wherein the splice protector consists of UV-curable adhesive. 
     
     
       13. A fiber optic assembly, comprising:
 first and second fiber optic ribbons, each comprising a plurality of optical fibers coupled in an arrangement where the optical fibers are aligned side-by-side with one another, wherein the optical fibers of the first ribbon are spliced with the optical fibers of the second ribbon such that the spliced ribbons at the splice have a common lengthwise axis, widthwise axis orthogonal to the lengthwise axis, and thickness axis orthogonal to the lengthwise and widthwise axes; and 
 a splice protector supporting the optical fibers of the first and second fiber optic ribbons that are spliced to one another at the splice, 
 wherein the splice protector consists essentially of an adhesive that provides a flexible support for the splice, wherein the splice protector and the splice are bendable around curved surfaces about the widthwise axis, and 
 wherein the splice protector is at least 60% as flexible as the first and second ribbons in bending about the widthwise axis at the splice. 
 
     
     
       14. The fiber optic assembly of  claim 13 , wherein the splice protector consists of the adhesive. 
     
     
       15. The fiber optic assembly of  claim 14 , wherein the adhesive is an ultra-violet light (UV-) curable adhesive. 
     
     
       16. The fiber optic assembly of  claim 13 , wherein the splice protector has a low-profile, having a thickness in the thickness axis that is less than 1 mm thicker than either the first or second optical fibers fiber optic ribbons in the thickness axis. 
     
     
       17. The fiber optic assembly of  claim 13 , wherein the splice protector has a narrow-profile, having a width in the width widthwise axis that is less that than 1 mm wider than either the first or second optical fibers fiber optic ribbons in the width widthwise axis. 
     
     
       18. The fiber optic assembly of claim 1, further comprising:
 a fiber optic cable comprising the first and second fiber optic ribbons, wherein the fiber optic cable includes a jacket surrounding the splice protector.    
     
     
       19. The fiber optic assembly of claim 7, further comprising:
 a fiber optic cable comprising the first and second fiber optic ribbons, wherein the fiber optic cable includes a jacket surrounding the splice protector.    
     
     
       20. A fiber optic assembly, comprising:
 first and second fiber optic ribbons, each comprising a plurality of optical fibers coupled in an arrangement where the optical fibers are aligned side-by-side with one another, wherein the plurality of optical fibers of the first fiber optic ribbon are joined to the plurality of optical fibers of the second fiber optic ribbon by a fusion splice such that the spliced first and second fiber optic ribbons have a common lengthwise axis in a region of the fusion splice, a common widthwise axis orthogonal to the lengthwise axis at the fusion splice, and a common thickness axis orthogonal to the lengthwise and widthwise axes at the fusion splice; and   a splice protector comprising a solid thermoplastic material encapsulating the fusion splice and providing a flexible support for the pluralities of optical fibers of the first and second fiber optic ribbons at the fusion splice, wherein the splice protector and the fusion splice are bendable around curved surfaces about the widthwise axis, and wherein the splice protector comprises at least one of the following features (i) to (iii):
 (i) the splice protector has a low-profile, having a thickness along the thickness axis that is less than 0.75 mm thicker than either the first fiber optic ribbon or the second fiber optic ribbon along the thickness axis; 
 (ii) the splice protector has a narrow-profile, having a width along the widthwise axis that is less than 1 mm thicker than either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis; or 
 (iii) the splice protector is bendable to conform to a surface of a 1.25 inch mandrel.  
   
     
     
       21. The fiber optic assembly of claim 20, wherein the splice protector has a low-profile, having a thickness along the thickness axis that is less than 0.75 mm thicker than either the first fiber optic ribbon or the second fiber optic ribbon along the thickness axis.  
     
     
       22. The fiber optic assembly of claim 20, wherein the splice protector has a narrow-profile, having a width along the widthwise axis that is less than 1 mm thicker than either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis.  
     
     
       23. The fiber optic assembly of claim 20, wherein the splice protector is bendable to conform to a surface of a 1.25 inch mandrel.  
     
     
       24. The fiber optic assembly of claim 20, wherein the splice protector is at least 60% as flexible as the first and second fiber optic ribbons in bending about the widthwise axis.  
     
     
       25. The fiber optic assembly of claim 20, wherein the splice protector is devoid of a substrate configured to provide extra strength to the fusion splice.  
     
     
       26. The fiber optic assembly of claim 20, comprising at least one of the following features (a) or (b): (a) the splice protector has a thickness along the thickness axis that is less than 0.5 mm thicker than either the first fiber optic ribbon or the second fiber optic ribbon along the thickness axis, or (b) the splice protector has a width along the widthwise axis that is less than 0.5 mm wider than either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis.  
     
     
       27. The fiber optic assembly of claim 20, wherein the splice protector is devoid of a heat shrinkable tube surrounding at least a portion of the fusion splice.  
     
     
       28. A fiber optic assembly, comprising:
 first and second fiber optic ribbons each comprising a plurality of optical fibers coupled in an arrangement where the optical fibers are aligned side-by-side with one another, wherein the optical fibers of the first ribbon are spliced with the optical fibers of the second ribbon by a fusion splice such that the spliced ribbons at a region of the fusion splice have a common lengthwise axis, have a common widthwise axis orthogonal to the lengthwise axis, and are substantially arranged in a common plane; and   a splice protector consisting essentially of a solid thermoplastic material encapsulating and providing a flexible support for the first and second fiber optic ribbons at the fusion splice;   wherein the splice protector and the fusion splice are bendable around curved surfaces about the widthwise axis, and   wherein the splice protector is devoid of a substrate defining a cavity containing the solid thermoplastic material.    
     
     
       29. The fiber optic assembly of claim 28, wherein the splice protector is further devoid of any substrate configured to provide extra strength to the fiber optic assembly at the fusion splice.  
     
     
       30. The fiber optic assembly of claim 28, wherein the splice protector is devoid of a heat shrinkable tube surrounding at least a portion of the fusion splice.  
     
     
       31. The fiber optic assembly of claim 28, wherein the splice protector has a width along the widthwise axis that is less than 1 mm wider than either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis.  
     
     
       32. The fiber optic assembly of claim 28, wherein the splice protector has a width along the widthwise axis that is at least 0.5 mm greater than either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis.  
     
     
       33. The fiber optic assembly of claim 28, further comprising:
 a fiber optic cable comprising the first and second fiber optic ribbons, wherein the fiber optic cable includes a jacket surrounding the splice protector.    
     
     
       34. The fiber optic assembly of claim 28, wherein:
 the plurality of optical fibers of the first fiber optic ribbon includes fiber optic segments extending from a ribbonized portion of the first fiber optic ribbon;   the plurality of optical fibers of the second fiber optic ribbon includes fiber optic segments extending from a ribbonized portion of the second fiber optic ribbon; and   the thermoplastic material of the splice protector encapsulates an end of the ribbonized portion of the first fiber optic ribbon and an end of the ribbonized portion of the second fiber optic ribbon.    
     
     
       35. The fiber optic assembly of claim 28, wherein:
 the first and second fiber optic ribbons have a common thickness axis orthogonal to the lengthwise and widthwise axes at the fusion splice; and   the splice protector has a low-profile, having a thickness in the thickness axis that is less than 0.75 mm thicker than either the first or second fiber optic ribbons in the thickness axis.    
     
     
       36. The fiber optic assembly of claim 28, wherein the splice protector has a narrow-profile, having a width in the widthwise axis that is less than 1 mm wider than either the first or second fiber optic ribbons in the widthwise axis.  
     
     
       37. The fiber optic assembly of claim 36, wherein:
 the first and second fiber optic ribbons have a common thickness axis orthogonal to the lengthwise and widthwise axes at the fusion splice; and   the splice protector has a low-profile, having a thickness in the thickness axis that is less than 0.75 mm thicker than either the first or second fiber optic ribbons in the thickness axis.    
     
     
       38. A fiber optic assembly, comprising:
 first and second fiber optic ribbons each comprising a plurality of optical fibers coupled in an arrangement where the optical fibers are aligned side-by-side with one another, wherein the optical fibers of the first ribbon are spliced with the optical fibers of the second ribbon by a fusion splice such that the spliced ribbons at a region of the fusion splice have a common lengthwise axis and have a common widthwise axis orthogonal to the lengthwise axis; and   a splice protector consisting essentially of a solid thermoplastic material encapsulating and providing a flexible support for the first and second fiber optic ribbons at the fusion splice;   wherein the splice protector and the fusion splice are bendable to conform to a surface of a 1.25 inch mandrel; and   wherein the splice protector is devoid of a substrate defining a cavity containing the solid thermoplastic material.    
     
     
       39. The fiber optic assembly of claim 38, wherein the splice protector is further devoid of any substrate configured to provide extra strength to the fiber optic assembly at the fusion splice.  
     
     
       40. The fiber optic assembly of claim 38, wherein the splice protector is devoid of a heat shrinkable tube surrounding at least a portion of the fusion splice.  
     
     
       41. The fiber optic assembly of claim 38, wherein:
 the plurality of optical fibers of the first fiber optic ribbon includes fiber optic segments extending from a ribbonized portion of the first fiber optic ribbon;   the plurality of optical fibers of the second fiber optic ribbon includes fiber optic segments extending from a ribbonized portion of the second fiber optic ribbon; and   the thermoplastic material of the splice protector encapsulates an end of the ribbonized portion of the first fiber optic ribbon and an end of the ribbonized portion of the second fiber optic ribbon.    
     
     
       42. The fiber optic assembly of claim 38, further comprising:
 a fiber optic cable comprising the first and second fiber optic ribbons, wherein the fiber optic cable includes a jacket surrounding the splice protector.    
     
     
       43. The fiber optic assembly of claim 38, wherein the splice protector has a maximum dimension along the widthwise axis that is less than 1 mm greater than a maximum dimension of either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis.  
     
     
       44. The fiber optic assembly of claim 38, wherein the splice protector has a maximum dimension along the widthwise axis that is at least 0.5 mm greater than a maximum dimension of either the first fiber optic ribbon or the second fiber optic ribbon along the widthwise axis.