Patent Publication Number: US-2020278511-A1

Title: Ribbonizing methods and assemblies

Description:
FIELD 
     The present disclosure relates generally to improved methods and assemblies for ribbonizing loose optical fibers. 
     BACKGROUND 
     In the fiber optics industry, optical fibers are frequently spliced, stripped, cleaned, cleaved, and/or otherwise processed for a variety of purposes. In many cases, the optical fibers are ribbonized, such that the fibers are suitably arranged and, in many cases, color-coded, prior to processing. 
     Known ribbonizing processes typically involve gluing or taping of the optical fibers together. Such processes are time-consuming and imprecise, and can further cause contamination of machines such as splicers which are utilized in the subsequent processing of the optical fibers. Accordingly, improved ribbonizing methods and apparatus which are more efficient and precise, and which can reduce or prevent such contamination risks, would be advantageous. 
     Further, conventionally known optical fibers and fiber optic ribbons utilize nominal 250 micron diameter optical fibers. However, recently, nominal 200 micron diameter optical fibers have been developed. This size reduction inhibits the use of standard equipment, such as splicing equipment, previously utilized with nominal 250 micron diameter optical fibers. For example, a typical ribbonized plurality of nominal 200 micron diameter optical fibers would have a nominal 200 micron pitch spacing throughout the ribbonized array. However, most standard equipment is suited for optical fibers which are ribbonized at a nominal 250 micron pitch spacing. Accordingly, improved ribbonizing methods and apparatus which can efficiently and precisely provide pitch conversions for optical fibers would be advantageous. 
     BRIEF DESCRIPTION 
     Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention. 
     In accordance with one embodiment, a method for ribbonizing a plurality of loose optical fibers is provided. The method includes aligning the plurality of loose optical fibers in a co-planer array. The method further includes securing the aligned plurality of loose optical fibers in a predetermined pitch spacing, wherein each of the plurality of optical fibers is free from others of the plurality of optical fibers. The method further includes loading the loose optical fibers into a fiber holder. 
     In accordance with another embodiment, a method for ribbonizing a plurality of loose optical fibers is provided. The method includes aligning the plurality of loose optical fibers in a co-planer array. The method further includes arranging the aligned plurality of loose optical fibers into a pitch control device such that the plurality of loose optical fibers are converted from a first pitch spacing to a second pitch spacing different from the first pitch spacing in the pitch control device. The method further includes securing the arranged plurality of loose optical fibers in the pitch control device. The method further includes loading the secured loose optical fibers into a fiber holder at the second pitch spacing. 
     In accordance with another embodiment, a ribbonizing assembly is provided. The ribbonizing assembly includes an alignment device comprising a slot. The ribbonizing assembly further includes a pitch control device including a plurality of fiber channels, the fiber channels each having a size, shape, and spacing which provide a predetermined pitch spacing. The ribbonizing assembly further includes a clamp operable to interact with the pitch control device. The ribbonizing assembly further includes a removable fiber holder. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF FIGURES 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
         FIG. 1  is a perspective view of a ribbonizing assembly during alignment of loose optical fibers in accordance with embodiments of the present disclosure; 
         FIG. 2  is a perspective view of a ribbonizing assembly after arranging, securing, and loading of the loose optical fibers in accordance with embodiments of the present disclosure; 
         FIG. 3  is a perspective view of a ribbonizing assembly during removal of a fiber holder in accordance with embodiments of the present disclosure; 
         FIG. 4  is a perspective view of a plate of an alignment device in accordance with embodiments of the present disclosure; and 
         FIG. 5  is a perspective view of a pitch control device in accordance with embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     Referring now to  FIGS. 1 through 5 , methods and apparatus for ribbonizing optical fibers are provided. Methods and apparatus in accordance with the present disclosure provide numerous improvements and advantages over known ribbonizing processes. For example, methods and apparatus in accordance with the present disclosure advantageously facilitate relatively more efficient and precise ribbonizing. Further, such methods and apparatus may eliminate the need to glue, tape, or otherwise fasten the optical fibers together during the ribbonizing process, thus reducing or preventing contamination risks. Further, in exemplary embodiments, methods and apparatus in accordance with the present disclosure advantageously facilitate efficient and precise pitch conversion. 
     A plurality of loose optical fibers  10  may be provided for ribbonizing in accordance with the present disclosure. The loose optical fiber  10 , by virtue of being loose, are not bound to each other in the form of a fiber optic ribbon. The optical fibers  10  can be single-mode optical fibers, multi-mode optical fibers, or otherwise. Further, the optical fibers can have any suitable nominal diameter. For example, in some embodiments, the nominal diameter of each optical fiber  10  in the plurality of loose optical fibers  10  may be 200 microns. Alternatively, the nominal diameter of each optical fiber  10  in the plurality of loose optical fibers  10  may be 250 microns. In still other embodiments, other suitable diameters may be utilized. Notably, the nominal diameter is the nominal outer diameter of the outermost layer of the optical fiber  10 , which may for example be a secondary coating or a colorizing layer. 
     As shown, a ribbonizing assembly  20  may be utilized to ribbonize the plurality of loose optical fibers  10 . Ribbonizing assembly  20  may, for example, include a base  25 . Various other components of the ribbonzing assembly  20  may be attached to the base  25  in various configurations to form the ribbonizing assembly  20 , as discussed herein. 
     Ribbonizing assembly  20  may further include an alignment device  30 . The alignment device  30  may be a pivotable device which is pivotable between two or more positions, such as a loading position as illustrated in  FIG. 1 , a ribbonizing position as illustrated in  FIG. 2 , and an unloading position as illustrated in  FIG. 3 . The unloading position may, for example, be between the loading position and the ribbonizing position. The alignment device  30  may, for example, be pivotally connected to the base  25 , as shown. In these embodiments, the alignment device  30  may be pivotable relative to the base  25  between the various positions. 
     Alignment device  30  may include a slot  32  which may be defined between a first plate  34  and a second plate  36 . First plate  34  may include a planar inner surface  35 . As illustrated in  FIG. 4 , second plate  36  may include an inner surface  37  which defines a step  38 . Additionally, a bore hole  39  may be defined through the plate  36 , inner surface  37 , and step  38 . 
     The slot  32 , or a first portion thereof, may extend to the step  38 . This portion of the slot  32  may have a width which is slightly greater than the nominal diameter of the optical fibers  10  to be ribbonized. For example, the width of the slot  32  may be between 0% and 10%, such as between 2% and 8%, such as between 4% and 6%, greater than the nominal diameter of the optical fibers  10 . Accordingly, the optical fibers  10  can be inserted into the slot  32 . The step  38  may reduce or eliminate the width, such that the optical fibers  10  cannot be inserted into the slot  32  beyond the step  38 . In some embodiments, the slot  32  terminates at the step  38 . In other embodiments, the width of the slot  32  is reduced at the step  38  to less than the nominal diameter of the optical fiber  10 . 
     Alignment device  30  may further include a post  40  which extends through the bore hole  39 , and may further extend into the slot  32 , when the alignment device is in the ribbonizing position. Post  40  may contact the optical fibers  10  which extend across the bore hole  39 , holding the optical fibers  10  into position within the slot  32 . When the alignment device  30  is in the loading and unloading positions, the post  40  may not contact the optical fibers  10 , and may further not be disposed in the bore hole  39  and/or the slot  32 . In some embodiments, post  40  extend from base  25 , as shown. 
     Alignment device  30  may further include a plunger  42 . In some embodiments, plunger  42  extends from base  25 , as shown. Plunger  42  may further be movable relative to base  25  between a compressed position, as shown in  FIG. 2 , and an extended position, as shown in  FIGS. 1 and 3 . When the alignment device  30  is in the loading position or unloading position, the plunger  42  may be in the extended position. When the alignment device  30  is moved to the ribbonizing position, the plunger  42  may be in the compressed position. Plunger  42  may generally support the alignment device  30  in the unloading position such that the ribbonized fibers  10  can be unloaded therefrom. 
     Ribbonizing device  20  further includes a pitch control device  50 . In some embodiments, the pitch control device  50  may be attached to the base  25 , such as integral with the base  25  or embedded in the base  25  as shown. When embedded, at least a portion of the device  50  may be surrounded by the base  25 . For example, the pitch control device  50  may be formed (such as via 3-D printing) separate, inserted into the base  25 , and held in the base  25  with a set screw or other suitable fastener. In other embodiments, pitch control device  50  may be a portion of a fiber holder, as discussed herein. The pitch control device  50  may include a plurality of fiber channels  52  which extend in a co-planer, parallel manner. Each channel  52  may accommodate an optical fiber  10  therein. Further, the channels  52  may each have a size, shape, and spacing (relative to other channels  52 ) which provide a predetermined pitch spacing for the plurality of optical fibers  10  when arranged in the channels  52 . The size, shape, and spacing of the channels  52  may, in some embodiments, be dependent upon the nominal diameter of the optical fibers  10 , such that a desired predetermined pitch spacing is provided for the optical fibers  10  when arranged in the channels  52 . 
     In some embodiments, the predetermined pitch spacing may be constant throughout the entire lengths of the channels  52 , and thus throughout the pitch control device  50 . Alternatively, the predetermined pitch spacing may be adjusted within the pitch control device  50 , such as from a first pitch spacing to a second pitch spacing which is different from (such as larger or smaller than) the first pitch spacing. For example, referring to  FIG. 5 , each channel  52  may include a first end portion  54 , an intermediate portion  56 , and a second end portion  58 . The first end portions  54  may provide a first pitch spacing. The second end portions  58  may provide a second pitch spacing. The intermediate portions  56  may provide a transition between the first and second pitch spacings. Accordingly, optical fibers  10  arranged in the pitch control device  50 , such as in the channels  52  thereof, may be converted from a first pitch spacing to a second pitch spacing within the device  50  and channels  52  thereof. 
     In some embodiments, the first pitch spacing is nominal 200 microns and the second pitch spacing is 250 microns. Alternatively, other suitable first and second pitch spacings, and associated conversions therebetween, may be utilized. 
     Ribbonizing assembly  20  may further include one or more clamps  60 , each of which may include a contact pad  62 . Each clamp may be operable to interact with the pitch control device  50 . For example, each clamp  60  may be a pivotable device which is pivotable between two or more positions, such as an open position as shown in  FIGS. 1 and 3  and a closed position as shown in  FIG. 2 . In some embodiments, each clamp  60  may be pivotally connected to the base  25  and thus pivotable relative to the base  25 . The clamps  60  may be utilized to secure the optical fibers  10  in position in the pitch control device  50 . For example, in the open position, the clamps  60  may not be in contact with the device  50  or optical fibers  10  arranged therein. In the closed position, the clamps  60 , such as the pads  62  thereof, may contact the optical fibers  10  and pitch control device  50 , thus securing the optical fibers  10  in position in the pitch control device  50 . Notably, in some embodiments, the interaction between the clamps  60  and the pitch control device  50  allows each optical fiber  10  to be free from the others of the plurality of optical fibers  10  (and thus not, for example, glued or taped together) during ribbonizing and/or use of the ribbonizing assembly  20 . 
     Ribbonizing assembly  20  may further include a removable fiber holder  70 . In general, any suitable fiber holder  70  may be utilized. The fiber holder  70  may, in some embodiments, be removably connected to the base  25 , such as via alignment pegs  72  extending from the base  25  and corresponding holes defined in the fiber holder  70 . In some embodiments pitch control device  50  is a separate component from the fiber holder  70 , while in other embodiments pitch control device  50  is a component of the fiber holder  70 . Fiber holder  70  may include a body  74  and a clamp  76  which is pivotally connected to the body  74 . 
     The body  74  may include channels which may accommodate optical fibers  10  therein. Similar to channels  52 , the channels of the body  74  may each have a size, shape, and spacing (relative to other channels) which provide a predetermined pitch spacing for the plurality of optical fibers  10  when arranged in the channels. The size, shape, and spacing of the channels may, in some embodiments, be dependent upon the nominal diameter of the optical fibers  10 , such that a desired predetermined pitch spacing is provided for the optical fibers  10  when arranged in the channels. In some embodiments, the size, shape, and/or spacing may correspond to the size, shape, and spacing of the channels  52  at the second end portion  58 . For example, in some embodiments, the channels may have the second pitch spacing. 
     The clamp  76  may be pivotally connected to the body  74  and pivotable between, for example, an open position as shown in  FIG. 1  and a closed position as shown in  FIGS. 2 and 3 . In the open position, the clamp  76  may not be in contact with optical fibers  10  arranged in the fiber holder  70 , such as in the body  74  thereof. In the closed position, the clamp  76  may contact the optical fibers  10 , thus holding the optical fibers  10  in position in the fiber holder  70 . The fiber holder  70  can then be removed from the ribbonizing assembly  20  and transported for use with other devices, such as for example, splicing, stripping, cleaning, cleaving, and/or other processing devices. 
     The present disclosure is further directed to methods for ribbonizing optical fibers  10 . In some embodiments, such methods and/or one or more of the various steps thereof may be performed using a ribbonizing assembly  20  or one or more components thereof as discussed herein. However, it should be understood that performance of methods in accordance with the present disclosure are not limited to utilization of ribbonizing assemblies  20  or components thereof, and rather that such methods may be performed using any suitable apparatus. Reference to ribbonizing assemblies  20  or components thereof during discussion of methods for ribbonizing optical fibers  10  in accordance with the present disclosure are merely for illustrative purposes and are not intended to be limiting. 
     A method for ribbonizing a plurality of loose optical fibers  10  may, for example, include the step of aligning the plurality of loose optical fibers  10  in a co-planer array. When in the co-planer array, the loose optical fibers  10  (such as the portions of the optical fibers  10  in the array) may further be generally parallel to each other. 
     In exemplary embodiments, such alignment may include, and result from, inserting the loose optical fibers  10  into a slot  32  of an alignment device  30 . For example, a first optical fiber  10  may be inserted into the slot  32  until it abuts against a step  38 , and the remaining optical fibers  10  may be inserted into the slot  32  such that each optical fiber  10  abuts against neighboring optical fibers  10 . In some embodiments such insertion may be performed with the alignment device  30  in a loading position, as illustrated in  FIG. 1 . Once the optical fibers  10  are aligned in the slot  32 , the alignment device  30  may be rotated to a ribbonizing position, as illustrated in  FIG. 2 . In some embodiments, a post  40  may contact the optical fibers  10  in the ribbonizing position to hold the optical fibers  10  in place in the aligned co-planer array. 
     When the plurality of loose optical fibers  10  are aligned in the co-planer array, the optical fibers  10  if including colorizing layers may in exemplary embodiments be aligned in color-coded order. 
     A method in accordance with the present disclosure may further include, for example, the step of arranging the aligned plurality of loose optical fibers  10  at a predetermined pitch spacing. Such arrangement may, for example, be done in a pitch control device  50 . For example, a user may, after performing the aligning step as discussed herein (optionally including rotation of an alignment device  30  from a loading position to a ribbonizing position), place further portions of the optical fibers  10  into a pitch-controlled arrangement (such as into a pitch control device  50 , e.g. channels  52  thereof). Notably, during such arranging, the optical fibers  10  may in exemplary embodiments be free from each other (and thus not, for example, glued or taped together). 
     In exemplary embodiments, such arranging may occur such that the optical fibers  10  are converted from a first pitch spacing to a second pitch spacing which is different from (such as greater than or less than) the first pitch spacing. Such arrangement may, for example, be done in a pitch control device  50 . 
     A method in accordance with the present disclosure may further include, for example, the step of securing the aligned plurality of loose optical fibers  10  in a predetermined pitch spacing, such as the predetermined pitch spacing provided during the arranging step. The securing step may occur, for example, after the aligning step and after the arranging step. Such predetermined pitch spacing may be a single pitch spacing throughout a portion of the plurality of loose optical fibers  10 , or a conversion of a portion of the plurality of loose optical fibers  10  from a first pitch spacing to a second pitch spacing different from the first pitch spacing as discussed herein. Notably, during such securing, the optical fibers  10  may in exemplary embodiments be free from each other (and thus not, for example, glued or taped together). 
     In some embodiments, such as for example when a pitch control device  50  is utilized, the securing step may include clamping the plurality of loose optical fibers  10 . For example, in some embodiments, clamps  60  may be pivoted from open positions to closed positions, as discussed herein. 
     A method in accordance with the present disclosure may further include, for example, the step of loading the loose optical fibers  10  into a fiber holder, such as fiber holder  70 . Such step may, in some embodiments, occur after the securing step. The optical fibers  10  may, for example, be loaded into the fiber holder  70  at the predetermined pitch spacing. In some embodiments, the predetermined pitch spacing may be the second pitch spacing facilitated via a pitch conversion. Alternatively, such loading step may occur before the securing step. For example, the pitch control device  50  may be a portion of the fiber holder  70 , and the predetermined pitch spacing may be adjusted during loading of the optical fibers  10  into the fiber holder  70 . In these embodiments, clamp(s)  60  may be the clamp(s)  76  of the fiber holder  70 . Such loading may include, for example, inserting portions of the secured optical fibers  10  into the fiber holder  70 , such as into a body  74  thereof Such loading may further include, for example, pivoting a clamp  76  of the fiber holder  70  to a closed position which holds the optical fibers  10  such that the optical fibers  10  are loaded into the fiber holder  70 . 
     In some embodiments, after such loading, the loaded optical fibers  10  may be unsecured. For example, in some embodiments, clamps  60  may be pivoted from closed positions to open positions. Further, in some embodiments, after such loading, the loaded optical fibers  10  may be removed from any arranging and aligning apparatus utilized during arrangement and alignment as discussed herein. Such removal may, in some embodiments such as when for example an alignment device  30  is utilized, include pivoting of the alignment device from a ribbonizing position to an unloading or loading position. After such pivoting, the optical fibers may be removed from the alignment device  30 . 
     A method in accordance with the present disclosure may further include, for example, removing the loaded fiber holder  70  (such as from a ribbonizing assembly  20 ). Such removal may occur after loading as discussed herein, as well as after unsecuring and removal of arranging and aligning apparatus as discussed herein. 
     A method in accordance with the present disclosure may further include, for example, transporting the loaded fiber holder  70  to a splicing, stripping, cleaning, cleaving, and/or other processing device for subsequent processing thereof. Such transporting step may occur after removal as discussed herein. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.