AMD METHODS AND DEVICES FOR MAKING THE SAME

Cross-Reference to Related Application This application is being filed on February 15, 2022 as a PCX International

Patent Application and claims the benefit of U.S. Patent Application Serial No.

63/149,562, filed on February' 15, 2021, the disclosure of which is incorporated herein by reference in its entirety.

Background Fiber optic communication systems are becoming prevalent in past because sendee providers want to deliver high bandwidth communication capabilities (e.g., data and voice) to customers. Fiber optic communication systems employ a network of fiber optic cables to transmit large volumes of data and voice signal s over relatively long distances. Optical fiber splices are an important part of most fiber optic communication systems. Optical fiber splices are typically used to provide a permanent or near permanent optical connection between optical fibers. Optical splices can include single fiber splices and multi-fiber splices (e.g., mass fusion splices). In a common splicing operation, two optical fibers or two sets of optical fibers are first eo-axiaiiy aligned. Often opto-eleetronic equipment is used to provide active alignment of the cores of the optical fibers. Once the optical fibers have been aligned, the ends of the optical fibers can be fusion spliced together usually by an electric arc.

After splicing, the splice location is typically reinforced with a fiber optic fusion splice protector. A common type of fiber optic fusion splice protector is a SMOUV fiber optic fusion splice protector sold by CommScope Inc. of Hickory, North Carolina,

U SA. This type of fusion splice protector includes an outer shrink-fit tube, a low temperature hot melt adhesive, and a stainless steel or ceramic rod which functions to add rigidity to the protector and to reinforce the splice location.

Improvements are desired. Summary

Some aspects of the disclosure are directed to a protective package positioned over fusion splice locations of at least first, second and third pairs of optical fibers. The protective package includes a shape-memory sleeve in which the fusion splice locations are located. The protective packaging also includes a reinforcing member positioned within the shape-memory sleeve. The reinforcing member defines a pocket facing toward the first, second and third pairs of optical fibers.

The first, second and third pairs of optical fibers are arranged in a non- coplanar configuration within the protective package, in certain examples, at least one of the pairs of optical fibers is disposed within the pocket. In certain examples, the first, second, and third pairs of optical fibers fonn optical fiber ribbons. In certain examples, tire pairs fonn loose fiber ribbons, in such examples, the optical fibers of the loose ribbons can be rolled, bunched, folded, or otherwise pushed together within the protective packaging.

Other aspects of the disclosure are directed to a device for forming the protective package. The device includes tire reinforcing member disposed within the shape-memory sleeve when the shape-memory sleeve is disposed in its enlarged state.

The reinforcing member defines a pocket facing towards a splice receiving location.

In some implementations, the pocket is defined by a concave curvature into the reinforcing member. In other implementations, the pocket can be defined by one or more planar surfaces (e.g., a v-groove).

In certain implementations, solid adhesive is disposed within the shape- memory sleeve. In some examples, the solid adhesive forms a hollow shape such as a tube through winch the optical fibers can be routed. In other examples, the solid adhesive forms one or more solid blocks positioned at the pocket of the reinforcing member.

In certain implementations, the shape-memory sleeve is a heat shrink sleeve and the adhesive is a hot-melt adhesive.

In certain implementations, axial ends of the shape-memory sleeve are constricted (e.g., partially shrunk) to facilitate retaining the reinforcing member and/or adhesive within the shape-memory sleeve. The constricted ends facilitate transportation and/or storage of the device until needed for use.

In certain implementations, the device is configured to thread over one os- more optical fibers to be spliced. 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, winch are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of tire drawings is as follows:

FIG. 1 ts a perspecti ve view of an example device to form a protective packaging, the device including adhesive and a reinforcing member disposed inside a shape-memory sleeve;

FIG. 2 is a transverse cross-sectional view of the device of FIG. 1 taken along the 2-2. line of FIG. 1:

FIG. 3 is a transverse cross-sectional view of a first alternative reinforcing member suitable for use with the protective packaging device of FIG. 1;

FIG. 4 is a transverse cross-sectional view of a second alternative reinforcing member suitable for use with the protective packaging device of FIG. 1;

FIG. 5 is an enlarged view of one of the axial ends of the device of FIG. 1 showing the end constricted;

FIG. 6 is a side ele vational view of the device of FIG. 1 mounted over an optical splice between pairs of optical fibers; and

FIG. 7 is a transverse cross-sectional view of a protective package formed around the optical splice using the device of FIG. 1.

Detailed Description

Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated m 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 device 100 that forms a protective package 140 (e.g., see FIG. 5) around an optical fiber splice 106 between at least a first optical fiber 102 and a second optical fiber 104. In certain implementations, tire device 100 protects optical fiber splices 106 of multiple pairs of optical fibers 102, 104. For example, the device 100 can protect the optical fiber splices 106 between optical fibers 102 of a first fiber ribbon and optical fibers 104 of a second fiber ribbon. In certain examples, the first and second fiber ribbons include loose ribbons, which also can be referred to as tollable ribbons. In certain examples, a tollable ribbon has about twelve fibers per ribbon. It will be understood, however, that each ribbon may include a greater or lesser number of fibers.

A reliable ribbon refers to a set of optical fibers 102, 104 that are attached together in a sequential order in such a way that the optical fibers 102, 104 can move relative to each other while maintaining the sequential order. Accordingly, the reliable ribbon can be rolled, folded, bunched, or otherwise shaped into non-coplanar configurations while allowing the fiber sequence to be readily identified. Further, the reliable ribbon enables the fibers to be laid in a coplanar configuration for a splicing operation. In some implementations, the optical fibers 102, 104 are connected together at intermittent connection locations along the lengths of the fibers, in some such examples, the intermittent connections between fiber pairs are staggered from each other. In other such examples, the intermittent connections between fiber pairs arc not staggered from each other. In other examples, the optical fibers 102, 104 are continuously coupled together along their length by a connection matrix. In some such examples, one side of the matrix is thinner than the other. In other such examples, slits are made in the connection matrix to enhance flexibility.

Examples of reliable ribbons are disclosed in U.S. PatentNos. 10, 185, 105; 9,880,368; 10,488,609; 10,007,078; 9,995,896; 9,086,555; 10,416,403; 9,116,321; 10,514,517; 9,989,723, 10,101,549, the disclosures of which are hereby incorporated herein by reference in their entirety'. Examples of reliable ribbons also are disclosed in U.S. Publication No. 2020/0271879, the disclosure of which is hereby incorporated herein by reference in its entirety. Other examples of loose ribbons of fibers include the Freeform Ribbon™ produced by Sumitomo of Japan, roliabie ribbons produced by OFS Furukawa of Norcross, GA, the SpiderWeb® Ribbon produced by AFL Telecommunications, LLC of Duncan, SC, and FlexRibbon™ of Prysmian Group of Italy.

The device 100 includes a shape-memory sleeve 110; an adhesive material

112 positioned within the shape-memory sleeve 110; and a reinforcing member 114 positioned within the shape-memory sleeve 110. The shape-memory sleeve 110 is moveable from an enlarged state to a reduced-size state. For example, the shape -memory sleeve 110 may be a heat-shrink sleeve. The reinforcing member protects the optical fiber splices 106 from being crushed when the shape-memory sleeve 110 is transitioned to its reduced-size state. In certain examples, when bonded to the fibers via the adhesive material 112, the reinforcing member 114 provides tensile and compressive reinforcement at the sphee location 106 and limits bending of the splice location 106. The shape of the reinforcing member 114 also can assist in controlling the cross-sectional shape of the fiber bunch as the shape-memory sleeve 110 reduces in size and, thus, the final cross-sectional shape (e.g., non-planar configuration; bunched/roiled state, etc.) of the fiber bunch.

The reinforcing member 114 defines a pocket or recessed region 116 in which at least a portion of the adhesive material 112 is positioned prior to reducing the size of the shape-memory sleeve 110. The pocket 116 faces toward an optical splice receiving location 118 within the shape-memory _' sleeve 110. When the shape-memory sleeve 110 is transitioned to the reduced-size state, the optical splices 106 and adhesive material 112 are pushed at least partially into the pocket 116 of the reinforcing member 114 (e.g., see FIG. 5).

In certain implementations, the shape-memory sleeve 110 has a length L1 between opposite first and second axial ends 124. 126. The shape-memory sleeve 110 also has a width Wi (FIG. 2) and a height H1 (FIG. 2) that are each orthogonal to the length L1 and to each other. The length L1 is greater than the width W 1 and the height HI. The length L1 is sufficient to extend fully over the optical splices 106 between the pairs of optical fibers 102, 104. In certain implementations, the width W1 and the height HI of the shape-memory' sleeve 110 are about equal (e.g., the shape-memory sleeve 110 has a generally circular cross-sectional shape), in other examples, the shape-memory sleeve 110 has an oblong cross-sectional shape.

In certain implementations, the reinforcing member 114 includes an elongate body having a length L2 (FIG. 1), a width W2 (FIG. 2), and a thickness T2 (FIG. 2). The reinforcing member 114 is oriented so that the length L2 extends along the length L1 of the shape-memory sleeve 110. The reinforcing member 114 includes first and second opposite sides 120, 122 separated by the thickness T2. The pocket 116 is defined at the first side 120. In certain examples, the pocket 116 is defined by a concave shape that extends across the width W2 of the reinforcing member 114. In some implementations, the reinforcing member 114 has a curved surface around a periphery (see FIG. 2) of the reinforcing member 114. in other implementations, the exterior surface of the reinforcing member 114 can have one or more planar portions around the periphery (e.g., see FIG. 4). In some implementations, the pocket 116 is defined by a concave curvature (e.g., see FIG. 2). In other implementations, the pocket 116 can be defined by one or more planar surfaces (e.g., see FIGS. 3 and 4). For example, the reinforcing member 114 of FIG. 3 has a v-groove shaped pocket 116. In FIG. 4, the pocket 116 has a rectangular shape.

In certain implementations, tire reinforcing member 114 has a convex surface opposite a concave surface. For example, the first side 120 defines a concave surface to fonn the pocket 116 and the second side 122 defines a convex surface aligned with the concave surface (e.g., see FIG. 2). In certain examples, a transverse cross- sectional profile of the reinforcing member forms an arc. In certain examples, the reinforcing member 114 is formed by curving a flat, elongate piece of metal along a dimension that extends along the width W2 of the reinforcing member 114.

In certain implementations, the adhesive material 112 is solid before the device 100 is shrunk over a splice region. In some implementations, the adhesive material 112 is formed into a tube or other hollow shape. In such implementations, the hollow shape is sized to receive the reliable ribbons within the interior thereof, in other implementations, the adhesive material 112 defines an elongate block of material that does not define a through passage. In some examples, the block of material seats at least partially within the pocket 116. In other examples, the block of material is too large to fit within the pocket 116.

In certain implementations, the adhesive material 112 is a hot-melt adhesive that melts and flows within the shape-memory _' sleeve 110 to fill voids and provide bonding between the optical fibers 102, 104, the reinforcing member 114, and the shape-memory _' sleeve 110. In certain implementations, tire adhesive material 112 is sized to extend along at least a majority of the length L2 of the reinforcing member 114. In certain examples, the adhesive material 112 extends fully along the length L2 of the reinforcing member 114. In certain examples, the adhesive material 112 extends beyond the axial ends of the reinforcing member 114.

The device 100 is formed by disposing the reinforcing member 114 and the adhesive material 112 within an interior of the shape-memory sleeve 1 10. For example, the reinforcing member 114 and the adhesive material 112 can be slid into the shape- memory sleeve 110. In other examples, the reinforcing member 114 can be laid upon the adhesive material 112 and the shape-memory sleeve 110 can be slid over the combination of the reinforcing member 114 and the adhesive material 112.

In certain implementations, the axial ends 124, 126 of the shape-memory sleeve 110 can be constricted (e.g., partially shrunk) sufficient to retain the reinforcing member 114 and adhesive material 112 within the shape-memory sleeve 110 (e.g., see FIG. 5). After shrinking, the axial ends 124, 126 define axial openings leading to the interior of the shape-memory sleeve 110, the axial openings having sufficient size to enable threading of optical fibers 102, 104 through the shape-memory sleeve 110. In some examples, the axial ends 124, 126 are constricted evenly so that the axial openings to the shape-memory sleeve 110 are centered along a longitudinal axis of the shape-memory sleeve 110. In other examples, the axial ends 124, 126 are constricted so that the axial opening extends at a non-ninety _' degree angle to the longitudinal axis L,

Accordingly, the device 100 can be pre-formed before the fibers need to be spliced and stored until needed. In certain examples, the device 100 can be utilized at a different location from where tire device 100 is formed. For example, the de vice 100 can be manufactured at a factory _' , but used in the field to protect an optical splice. In another example, the device 100 can be manufactured at one facility or room within a facility and applied over an optical splice at another facility or another room within the same facility.

When a protective package 140 is desired, the device 100 is slid onto one of the optical fibers 102 of each pair 102, 104 to be spliced together prior to the splicing so that the optical fibers 102 extend fully through the shape-memory sleeve 110. In certain examples, the one or more optical fibers 102 extend through the tube of adhesive material 112. In other examples, the one or more optical fibers 102 extend between the pocket 116 of the reinforcing member and the block of adhesive material 112. In still other examples, the adhesive material 112 extends between tire one or more optical fibers 102 and the pocket 116.

In certain implemen tations, the ends of the optical fibers 102, 104 to be spliced are stripped of any connecting material (e.g., matrix material) to prepare the optical fibers 102, 104 for splicing. The acrylate coatings of the optical fibers 102, 104 also may be stripped. The stripped fiber ends are aligned with each other in sequential order and spliced to their corresponding pairs at a location outside of the shape-memory sleeve 110. For example, the fibers may be arranged in a planar array and spliced while in the planar configuration.

Once the splice 106 is formed, the device 100 is slid over the splice 106 so that the splice 106 is disposed within the shape-memory sleeve 110. In some implementations, the spliced fibers are arranged in a non-coplanar configuration prior to sliding the device 100 over the splice region 106. For example, the fibers can be rolled after splicing, but before insertion in the device 100 to form protective package 140. In various examples, the spliced optical fibers 102, 104 may be rolled, folded, bunched together, or otherwise fit into the device 100. in other implementations, the spliced fibers are inserted into the device 100 in a eoplanar array.

In certain examples, the splice region 106 is disposed within the tube of adhesive material 112. Accordingly, the spliced optical fibers 102, 104 are arranged into a shape that fits within the tube. In some examples, the spliced optical fibers 102, 104 are arranged in a eoplanar configuration. In other examples, the spliced optical fibers 102,

104 are arranged in a ring configuration (e.g., see FIG. 2). In other examples, the spliced optical fibers 102, 104 may be arranged in any desired configuration (e.g., spiral, folded, v-shaped, bunched, etc.).

When the device 100 is positioned around the splice 106, the shape- memory sleeve 110 is transitioned to the reduced-size state. For example, heat may be applied to the shape-memory sleeve 110 along the length L1 of the shape-memory sleeve 110. In certain implementations, the heat melts the adhesive material 112. so that the adhesive material 112 flows around the optical fiber pairs 102, 104. In certain examples, the adhesive material 112 flows into the pocket 116 of the reinforcing member.

Shrinking of the shape-memory sleeve 110 can make the rolled or otherwise non-coplanar configuration of the fibers more compact. For example, the fibers may transition from a loosely rolled configuration to a compactly bunched configuration. In certain implementations, the shape of compact bunching is at least in part controlled by the shape of the pocket 116 of the reinforcing member 114.

As the shape-memory sleeve 110 reduces in size, the shape-memory sleeve 110 applies a pressure to the spliced optical fibers 102, 104 to push the optical fibers 102, 104 towards the pocket 116 of the reinforcing member 114. The pocket 116 is sized to receive at least some of the adhesive material 112 and spliced optical fibers 102, 104, thereby reducing an overall transverse cross-sectional profile of the device 100. in certain examples, the optical fibers 102, 104 have a resulting non-coplanar configuration along the transverse cross-section of the splice 106. For example, the optical fibers 102, 104 can be bunched together with little space therebetween (e.g., see FIG. 7),

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.