Cross-Reference to Related Applications

This application is being filed on October 20, 2022 as a PCT International Patent Application and claims the benefit of U.S. Patent Application Serial No. 63/257,864, filed on October 20, 2021 and claims the benefit of U.S. Patent Application Serial No. 63/311,288, filed on February 17, 2022, the disclosures of which are incorporated herein by reference in their entireties.

Background

Optical fiber cable assemblies are installed within central offices or datacenters by pulling the optical fiber cable assemblies through conduits routed through the buildings. Typically, the conduits have narrow diameters (e.g., 3 inches, 2 inches, 1.25 inches, etc.). Accordingly, the optical fiber cable assemblies are packaged to fit through the conduits. When preterminated with optical connectors, the amount of room to pull these cable assemblies through the conduits becomes tight. However, the optical fiber cable assemblies must be pulled through the conduits without damage to the fibers or to the connectors. Improvements are desired.

Summary

Aspects of the present disclosure are directed to a cable pulling arrangement for use in pulling a cable assembly. The cable pulling arrangement includes multiple tubing members that mount over a cable assembly to provide crush resistance. The tubing members are disposed end-to-end. The tubing members are not directly coupled together and, therefore, the axial ends are free to move relative to each other by at least a limited amount. This freedom of movement allows the cable assembly to flex (e.g., through a tortuous conduit) beyond the bend radius of each individual tubing member.

In certain implementations, the tubing members are mounted over a plastic sleeve that extends over a portion of the cable. In certain examples, the plastic sleeve provides water resistance to the portion of the cable. In certain examples, the portion of the cable includes portions of cable sub-units extending beyond a jacketed main portion of the cable assembly.

In certain implementations, a mesh sleeve can be disposed over the tubing members. The mesh sleeve is secured at both axial ends. A first axial end of the mesh sleeve is secured to the main portion of the cable assembly or to a fanout of the cable assembly to provide sufficient strength to pull the cable by the mesh sleeve. A second axial end of the mesh sleeve is secured closed (e.g., to form a pulling loop).

A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.

Brief Description of the Drawings

The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:

FIG. 1 is a schematic depiction of a cable assembly including multiple cable sub-units extending outwardly from a main cable portion;

FIG. 2 shows an example implementation of connectorized ends of one or more cable sub-units of the cable assembly of FIG. 1 ;

FIG. 3 shows an example implementation of the connectorized ends of the cable sub-units bundled in separate bags;

FIG. 4 is a schematic depiction of the bags bundling connector groups of the cable sub-units;

FIG. 5 is a schematic depiction of a plastic sleeve disposed over the cable sub-units of FIG. 4 including over the bundled connector groups;

FIG. 6 is a schematic depiction of multiple discrete tubing members disposed over the plastic sleeve of FIG. 5;

FIG. 7 shows an example implementation of the cable assembly of FIG. 6 with an example implementation of a mesh sleeve laid alongside it;

FIG. 8 is a schematic depiction of the cable assembly of FIG. 6 with a mesh pulling sleeve mounted thereover; FIG. 9 is a schematic view of an example partitioned bag suitable for use in managing the connectors of the cable sub-units;

FIG. 10 shows the connectors of an example cable sub-unit disposed within an example partitioned bag where one of the connectors terminates shorter optical fibers than the other connectors of the sub-unit; and

FIG. 11 shows two partitioned bags staggered along the length of the cable assembly, each partitioned bag separately holding the connectors of one cable sub-unit of the cable assembly.

Detailed Description

Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

The present disclosure is directed to a pullable cable assembly, a pulling arrangement disposable around the cable assembly, and methods of manufacture thereof. The pulling arrangement is disposed around a cable assembly to enable the cable assembly to be pulled or otherwise routed along a conduit. In certain implementations, the pulling arrangement also provides crush resistance or otherwise protects the cable assembly. In certain implementations, the pulling arrangement maintains the relative placement of the connectorized ends of the cable assembly.

Referring to FIG. 1, a cable assembly 100 includes a main cable portion 102 including a plurality of cable subunits 104. The cable assembly 100 has an axial length CL extending between opposite ends of the cable assembly 100. The main cable portion 102 includes a jacket 103 that surrounds first portions of the cable subunits 104. Second portions of the cable subunits 104 extend past an end of the main cable portion 102. In certain implementations, a fanout 106 transitions the cable subunits 104 from the main cable portion 102. Example fanouts 106 suitable for use with the cable assembly 100 are provided in U.S. Publication No. 2021/0124140, the disclosure of which is hereby incorporated herein by reference in its entirety.

Each cable subunit 104 includes one or more optical fibers 108 that are terminated at optical connectors 112. In some implementations, each optical fiber 108 is separately connectorized at a single-fiber optical connector. In other implementations, multi-fiber optical connectors terminate multiple ones of the optical fibers 108. In certain implementations, the cable subunits 104 have different lengths, resulting in the optical connectors 112 being staggered along the length of the cable assembly 100. In certain examples, the optical fibers 108 are staggered in groups 113 (e.g., see FIGS. 3 and 11).

FIG. 2 illustrates two example groups 113 A, 113B of optical fibers 108. The fibers 108 of the first group 113A are longer than the fibers 108 of the second group 113B so that the optical connectors 112 terminating the fibers 108 of the first group 113A are offset from the optical connectors 112 terminating the fibers 108 of the second group 113B. In certain implementations, the optical fibers 108 of each group 113 transition from a cable subunit 104 at another fanout 110. In certain implementations, the optical fibers 108 of each group 113 are taped together.

As shown in FIGS. 3 and 4, each group 113 of connectors 112 can be separately bundled into a bag 114 or short sleeve. The bag 114 or short sleeve maintains the connectors 112 of each group 113 together during pulling of the cable assembly 100. The bag 114 of short sleeve also facilitates identification of each connector group 113 during installation of the cable assembly 100. In certain implementations, the bag 114 or short sleeve is formed of plastic. In certain examples, the bag 114 or short sleeve is translucent. In certain implementations, the bag 114 or short sleeve is secured around each group 113 using tape 116, a cable tie, a hook-and-loop strap, or other securement mechanism.

FIGS. 9-11 illustrate an alternative implementation of the bag 130 suitable for bundling the connectors 112 of a group 113. The bag 130 extends along a length BL from a closed end 132 to an open end 134 and along a width BW between opposite closed ends. The open end 134 provides access to an interior of the bag 130. The interior of the bag 130 is partitioned into separate chambers 136 that each extend along the length BL between the closed end 132 and the open end 134 of the bag 130. In certain examples, the chambers 136 are divided by heat seals 138. In some examples, each chamber 136 is fully sealed from the other chambers 136. In other examples, the heat seals 138 are interrupted along the length BL of the bag 130. In certain implementations, each chamber 136 is sized to receive a respective one of the connectors 112 of the group 113. Accordingly, the relative positions of the connectors 112 with respect to each other are maintained, thereby facilitating management of the optical fibers extending from the connectors 112.

In certain implementations, the chambers 136 of a bag 130 have a common size. In certain examples, the chambers 136 have widths sufficient to accommodate only one connector 112 (e.g., a simplex connector, a duplex connector, a multi-fiber connector, etc.) per chamber 136. In certain examples, each chamber 136 has a width of about 1 inch. In other examples, each chamber 136 can have a larger or smaller width (e.g., 0.5 inches, 1.5 inches, 2 inches, etc.). In certain implementations, the length BL of the bag 130 is defined to be larger than a length of any of the connectors 112. Accordingly, the bag 130 is sized to accommodate rework (e.g., resplicing of the optical fibers).

The connectors 112 can be positioned at any point along the length BL of the respective chambers 136. In the example shown in FIG. 10, the second connector 112b is disposed closer to the open end 134 of the bag 130 than the other connectors 112 (e.g., closer than the first connector 112a) because the second connector 112b was respliced to the second fibers 108b. The respective chamber 136 is sufficiently long to fully contain all of the connectors 112. In certain examples, the length BL of the bag 130 is at least double the length of one of the connectors 112. In certain examples, the length BL of the bag 130 is at least three times the length of one of the connectors 112. In certain examples, the length BL of the bag 130 is no more than three times the length of the one of the connectors 112. In certain examples, the length LB of the bag 130 is at lest 5 inches.

Referring now to FIG. 5, a sleeve 118 is pulled over the bundled groups 113 of connectors 112. In certain implementations, the sleeve 118 is pre-mounted on the main cable portion 102 before the connectors 112 are bundled in groups 113 and the sleeve 118 is slid over the bundled groups 113 from the main cable portion 102. In certain implementations, the sleeve 118 is formed of plastic. In certain examples, the sleeve 118 is translucent. In certain examples, the sleeve 118 extends fully over the second portions of the cable subunits 122. In certain examples, the sleeve 118 extends over the fanout 104.

In certain examples, the sleeve 118 is secured to the main cable portion 102 of the cable assembly 100 using tape 120, a cable tie, a hook-and-loop strap, or other securement mechanism. For example, the sleeve 118 may be secured to the jacket 103 of the main cable portion 102. In certain examples, the sleeve 118 is configured to provide water resistance to protect the optical connectors 112 and/or the optical fibers 108. In certain examples, the sleeve 118 has an internal diameter sized to fit sufficiently tightly over the cable subunits 104 to inhibit relative movement therebetween without radially compressing the connectors 112. In certain examples, a distal end of the sleeve 118 may be folded, crumpled, or otherwise closed. In certain examples, the distal end of the sleeve 118 may be held closed with tape, a clip, or another securement mechanism.

As shown in FIG. 6, crush resistance is provided by installing multiple tubing members 122 over the sleeve 118. Crushing forces can occur by radially directed compressive forces exerted by a mesh sleeve over the cables and the connectors 112, as will be described below. In certain implementations, the tubing members 122 are disposed end-to-end to extend along the axial length L of the cable assembly 100. The tubing members 122 may contact each other, but are not directly coupled to each other. In certain implementations, each tubing member 122 is sized to fit over a bundled group 113 of connectors 112. In certain implementations, each tubing member 122 is sized to fit over the fanouts 106, 110.

In certain implementations, the tubing members 122 have smooth outer circumferential walls. In certain implementations, the tubing members 122 have smooth inner circumferential walls. In certain implementations, each tubing member 122 has a constant inner diameter along the axial length L of the tubing member 122. In certain implementations, each tubing member 122 has a constant outer diameter along the axial length L of the tubing member 122. In certain implementations, the tubing members 122 have corrugated circumferential walls.

In some implementations, the tubing members 122 can be pre-mounted on the main cable portion 102 before terminating the cable subunits 104. In such implementations, the tubing members 122 can be slid over the sleeve 118 from the main cable portion 102. In other implementations, the tubing member 122 are slid over the sleeve 118 from the distal end of the cable subunits 114 towards the main cable portion 102. In certain implementations, the tubing members 122 are formed of plastic. In some implementations, the tubing members 122 are formed of butyrate. Other implementations are possible.

In certain implementations, each tubing member 122 has an outer diameter D that is no more than 3 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 2 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 1.9 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 1.8 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 1.7 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 1.25 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 1.2 inches. In certain examples, each tubing member 122 has an outer diameter D that is no more than 1. 1 inches.

In some examples, the tubing members 122 have a common axial length L. In other examples, the tubing members 122 may have different axial lengths L. In certain implementations, the tubing members 122 are each sized to have an axial length L between 1 inch and 10 inches long. In certain examples, the tubing members 122 are each sized to have an axial length L between 2 inches and 8 inches long. In certain examples, the tubing members 122 are each sized to have an axial length L between 1 inch and 6 inches long. In certain examples, each tubing member 122 is sized to have an axial length L between 2 inches and 4 inches long.

Referring to FIGS. 7 and 8, a mesh sleeve 124 is installed over the cable assembly 100 so that the tubing members 122 are disposed within the mesh sleeve 124. In some implementations, the mesh sleeve 124 is pre-installed over the main cable portion 102 before bundling the connector groups 113. In other implementations, the mesh sleeve 124 is slid over the cable assembly 100 and tubing members 122 from the distal end of the cable sub-units 104.

In certain implementations, a first axial end of the mesh sleeve 124 is secured to the main cable portion 102. For example, the first end of the mesh sleeve 124 may be secured by tape, a cable tie, a hook-and-loop strap, or other securement mechanism. In certain implementations, the first end of the mesh sleeve 124 is secured to the fanout 106 of the cable assembly 100. The mesh sleeve 124 has a second axial end 126 that is looped (e.g., see FIG. 7) or otherwise configured to enable attachment of a pulling cable or other pulling mechanism.

In certain implementations, the mesh sleeve 124 is configured to radially constrict when pulled axially. In certain implementations, the mesh sleeve 124 has a resting inner diameter (i.e., an inner diameter when no axial tension is applied to the mesh sleeve 124) of no less than 1.1 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 1.2 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 1.5 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 1.6 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 1.7 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 1.8 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 1.9 inches. In certain examples, the mesh sleeve 124 has a resting inner diameter of no less than 2 inches.

In certain implementations, the tubing members 122 can withstand a radial compressive force of the mesh sleeve 124 when a tensile load of at least 100 pounds is applied to the mesh sleeve 124. In certain implementations, the tubing members 122 can withstand a radial compressive force of the mesh sleeve 124 when a tensile load of at least 200 pounds applied to the mesh sleeve 124. In certain implementations, the tubing members 122 can withstand a radial compressive force of the mesh sleeve 124 when a tensile load of at least 300 pounds applied to the mesh sleeve 124. In certain implementations, the tubing members 122 can withstand a radial compressive force of the mesh sleeve 124 when a tensile load of at least 400 pounds applied to the mesh sleeve 124. In certain implementations, the tubing members 122 can withstand a radial compressive force of the mesh sleeve 124 when a tensile load of at least 500 pounds applied to the mesh sleeve 124. In certain implementations, the tubing members 122 can withstand a radial compressive force of the mesh sleeve 124 when a tensile load of at least 600 pounds applied to the mesh sleeve 124.

Aspects of the Disclosure

Aspect 1. A cable pulling assembly comprising: a cable assembly extending along a length, the cable assembly including a main cable including a jacket surrounding a plurality of cable subunits, the main cable having an end at which the jacket is terminated, the cable subunits extending past the end of the main cable, each cable subunit including a plurality of connectorized ends each terminated with a respective fiber optic connector; a plurality of bags, each bag being disposed over the plurality of connectorized ends of a respective one of the cable subunits, each bag defining a plurality of chambers, each chamber receiving one of the fiber optic connectors of the respective cable subunit; a plastic sleeve positioned over the cable assembly so that the plastic sleeve extends over a portion of the main cable and over the connectorized ends of the cable subunits; a crush-resistant arrangement positioned over the plastic sheet; and a mesh sleeve positioned over the plurality of crush-resistant arrangement.

Aspect 2. The cable pulling assembly of aspect 1, wherein the cable subunits have different lengths to stagger the fiber optic connector terminating the connectorized ends.

Aspect 3. The cable pulling assembly of aspect 1 or aspect 2, wherein the chambers of one of the bags have a common length.

Aspect 4. The cable pulling assembly of any of aspects 1-3, wherein the chambers are arranged in a row along a width of the bag.

Aspect 5. The cable pulling assembly of any of aspects 1-4, wherein the crushresistant arrangement includes a plurality of segmented tubes.

Aspect 6. The cable pulling assembly of any of aspects 1-4, wherein the crushresistant arrangement includes a corrugated continuous tube.

Aspect 7. The cable pulling assembly of any of aspects 1-6, wherein the bags are staggered from each other along the length of the cable assembly.

Aspect 8. A cable pulling assembly, comprising: a cable assembly extending along a length, the cable assembly including a main cable including a jacket surrounding a plurality of cable subunits, the main cable having an end at which the jacket is terminated, the cable subunits extending past the end of the main cable, each cable subunit including a connectorized end terminated with a fiber optic connector; a plastic sleeve positioned over the cable assembly so that the plastic sleeve extends over a portion of the main cable and over the connectorized ends of the cable subunits; a plurality of discrete tubing members positioned over the plastic sheet; and a mesh sleeve positioned over the plurality of discrete tubing members. Aspect 9. The cable pulling assembly of aspect 8, wherein the discrete tubing members are disposed end-to-end along the length of the cable assembly.

Aspect 10. The cable pulling assembly of aspect 8 or aspect 9, wherein the discrete tubing members are configured to provide crush resistance.

Aspect 11. The cable pulling assembly of any of aspects 8-10, wherein the discrete tubing members have an outer diameter of no more than 3 inches.

Aspect 12. The cable pulling assembly of aspect 11, wherein the discrete tubing members have an outer diameter of no more than 2 inches.

Aspect 13. The cable pulling assembly of aspect 12, wherein the discrete tubing members have an outer diameter of no more than 1.25 inches.

Aspect 14. The cable pulling assembly of any of aspects 8-13, wherein the discrete tubing members are formed from butyrate.

Aspect 15. The cable pulling assembly of any of aspects 8-14, wherein the discrete tubing members have a common outer diameter.

Aspect 16. The cable pulling assembly of any of aspects 8-15, wherein the discrete tubing members have a common inner diameter.

Aspect 17. The cable pulling assembly of any of aspects 8-16, wherein the discrete tubing members have a common axial length.

Aspect 18. The cable pulling assembly of any of aspects 8-17, wherein the discrete tubing members are transparent.

Aspect 19. The cable pulling assembly of any of aspects 8-18, wherein a fanout is disposed at the end of the main cable. Aspect 20. The cable pulling assembly of any of aspects 8-19, wherein each cable subunit includes a plurality of connectorized ends each terminated with a respective fiber optic connector.

Aspect 21. The cable pulling assembly of aspect 20, wherein the connectorized ends of the cable subunits are disposed within respective plastic bags that are disposed within the plastic sleeve.

Aspect 22. The cable pulling assembly of aspect 21, wherein each bag defines a plurality of chambers, each chamber receiving one of the connectors of the respective cable sub-unit.

Aspect 23. The cable pulling assembly of any of aspects 8-22, wherein the cable subunits have different lengths to stagger the fiber optic connector terminating the connectorized ends.

Aspect 24. The cable pulling assembly of any of aspects 8-23, wherein the tubing members have constant inner diameters.

Aspect 25. The cable pulling assembly of any of aspects 8-23, wherein the tubing members are corrugated.

Aspect 26. A method of assembling a cable assembly comprising: sliding a plastic sleeve from a main cable portion of a cable assembly over a plurality of cable subunits extending outwardly from the main cable portion, wherein the plastic sleeve is slid over the cable subunits until terminated ends of the cable subunits are disposed within the plastic sleeve; individually sliding a plurality of discrete tubing members end-to-end over the plastic sleeve when the terminated ends of the cable subunits are disposed within the plastic sleeve; and sliding a mesh sleeve over the discrete tubing members. Aspect 27. The method of aspect 26, further comprising bundling the terminated ends of the cable subunits into plastic bags prior to sliding the plastic sleeve over the cable subunits.

Aspect 28. The method of aspect 27, wherein bundling the terminated ends of the cable subunits into the plastic bags comprises sliding each of the terminated ends into a respective chamber of the respective plastic bag.

Aspect 29. The method of any of aspects 26-28, further comprising installing the cable assembly within a building by routing the cable assembly through a conduit having an inner diameter of no more than 2 inches.

Aspect 30. The method of aspect 29, wherein routing the cable assembly through the conduit comprises axially pulling on the mesh sleeve.

Aspect 31. A cable pulling assembly comprising: a cable assembly extending along a length, the cable assembly including a main cable including a jacket surrounding a plurality of cable subunits, the main cable having an end at which the jacket is terminated, the cable subunits extending past the end of the main cable, each cable subunit including a plurality of connectorized ends each terminated with a respective fiber optic connector; a plurality of bags, each bag being disposed over the plurality of connectorized ends of a respective one of the cable subunits, each bag defining a plurality of chambers, each chamber receiving one of the fiber optic connectors of the respective cable subunit; a pulling sleeve positioned over the cable assembly so that the pulling sleeve extends over a portion of the main cable and over the connectorized ends of the cable subunits;

Aspect 32. The cable pulling assembly of aspect 31, wherein the cable subunits have different lengths to stagger the fiber optic connector terminating the connectorized ends. Aspect 33. The cable pulling assembly of aspect 31 or aspect 32, wherein the chambers of one of the bags have a common length.

Aspect 34. The cable pulling assembly of any of aspects 31-33, wherein the chambers are arranged in a row along a width of the bag.

Aspect 35. The cable pulling assembly of any of aspects 31-34, wherein the bags are staggered from each other along the length of the cable assembly. Having described the preferred aspects and implementations of the present disclosure, modifications and equivalents of the disclosed concepts may readily occur to one skilled in the art. However, it is intended that such modifications and equivalents be included within the scope of the claims which are appended hereto.