Patent Publication Number: US-2023161124-A1

Title: Optical cable with routable fiber carrying subunit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of International Application Number PCT/US2021/041517 filed on Jul. 14, 2021, which claims priority to U.S. Provisional Application Ser. No. 63/054,861 filed on Jul. 22, 2020, the content of each of which is relied upon and incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     The present invention is related to optical fiber cables with subunits and more particularly to optical fiber carrying subunits having jackets with improved mechanical properties. Optical fiber cables are used to transmit data over distance. Generally, large distribution cables that carry a multitude of optical fibers from a hub are sub-divided at network nodes into routable subunits. Described herein are jackets for routable subunits in which the jacket provides adequate flexibility, robustness, and safety features, among other qualities. 
     SUMMARY 
     In one aspect, embodiments of the disclosure relate to an optical fiber cable including an outer jacket and a plurality of optical fiber carrying subunits. The outer jacket includes an inner surface and an outer surface that is an outermost surface of the optical fiber cable. A central bore extends within the inner surface in a longitudinal direction between first and second ends of the outer jacket. The plurality of optical fiber carrying subunits are located within the central bore, and each of the plurality of optical fiber carrying subunits includes a subunit jacket and a plurality of optical fibers. Each subunit jacket is located within the central bore and includes an inner surface and an outer surface. An inner bore extends within an inner surface of the subunit jacket in a longitudinal direction between first and second ends of the subunit jacket. The subunit jacket includes a first polymer composition including a low smoke, zero halogen material that has a storage modulus of no more than 2000 MPa at −20 (negative twenty) degrees Celsius. The plurality of optical fibers are located within the inner bore and extend in the longitudinal direction between the first and second ends of the subunit jacket. 
     In another aspect, embodiments of the disclosure relate to an optical fiber cable including an outer jacket and a plurality of optical fiber carrying subunits. The outer jacket includes an inner surface and an outer surface. The outer surface is an outermost surface of the optical fiber cable. A central bore extends within the inner surface in a longitudinal direction between first and second ends of the outer jacket. The plurality of optical fiber carrying subunits are located within the central bore, and each of the plurality of optical fiber carrying subunits includes a subunit jacket and a plurality of optical fibers. Each subunit jacket is located within the central bore. The subunit jacket includes an inner surface and an outer surface. An inner bore extends within an inner surface of the subunit jacket in a longitudinal direction between first and second ends of the subunit jacket. The subunit jacket includes a first polymer composition that includes a low smoke, zero halogen material having an elongation at break coefficient of at least 140%. The plurality of optical fibers are located within the inner bore and extend in the longitudinal direction between the first and second ends of the subunit jacket. 
     In yet another aspect, embodiments of the disclosure relate to a method of manufacturing an optical fiber cable. The includes unspooling a first optical fiber and extruding a first polymer composition around the first optical fiber to form a first subunit jacket. The first subunit jacket includes an inner surface and an outer surface. An inner bore extends within the inner surface in a longitudinal direction between first and second ends of the first subunit jacket. The first polymer composition includes a low smoke, zero halogen material. During extrusion, the first polymer composition of the first subunit jacket includes a drawdown ratio no more than 4. The method also includes unspooling a second optical fiber and extruding the first polymer composition around the second optical fiber to form a second subunit jacket. The second subunit jacket includes an inner surface and an outer surface. An inner bore extends within the inner surface in a longitudinal direction between first and second ends of the second subunit jacket. During extrusion, the first polymer composition of the second subunit jacket comprises a drawdown ratio no more than 4. The method also includes extruding a second polymer composition around the first subunit jacket and the second subunit jacket to form an outer jacket. The outer jacket includes an outer surface that is an outermost surface of the optical fiber cable 
     Additional features and advantages will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. 
     It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims. 
     The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and the operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings: 
         FIG.  1    depicts an optical fiber ribbon cable, according to an exemplary embodiment; 
         FIG.  2    depicts a cross-sectional of the optical fiber ribbon cable of  FIG.  1   , according to an exemplary embodiment; 
         FIG.  3    depicts a perspective view an optical fiber carrying subunit of  FIG.  1   , according to an exemplary embodiment; 
         FIG.  4    depicts a graph showing the storage modulus for various subunit jacket materials, according to exemplary embodiments; 
         FIG.  5    is a cross-section image of an optical fiber ribbon cable, according to an exemplary embodiment; 
         FIG.  6    is a cross-section image of an optical fiber ribbon cable, according to an exemplary embodiment; and 
         FIG.  7    is a method of manufacturing one or more ribbon cables, according to an exemplary method. 
     
    
    
     While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims. 
     DETAILED DESCRIPTION 
     Referring generally to the figures, various embodiments of an optical fiber cable including subunits are shown. The subunit jackets discussed herein are formed from materials that provide a unique and difficult to achieve set of properties including, high burn resistance, low smoke production, flexibility, improved manufacturability and/or low thickness, that Applicant believes is not previously achieved in optical fiber subunit designs. Computer data center operators require increasingly high fiber density optical cables in order to meet their capacity needs while not overcrowding the trays used to run cables throughout the data center. To address this issue, Applicant has developed cables that use routable subunits. However, Applicant has found it difficult to obtain subunits with jackets that tolerate a high draw and thin wall manufacturing process, adhere to certain safety regulations (e.g., fire safety regulations), are sufficiently flexible, and do not exhibit unacceptable signal attenuation. Applicant has developed a variety of optical fiber cables with subunit jackets that are robust over a wide range of temperatures, flexible enough at room temperature to serve as a furcation leg, and can be used as a component in large stranded cables such as the 6912 IO cable without negatively impacting signal attenuation, all while achieving burn performance to satisfy various safety regulations. 
     The subunit jackets described herein provide several advantages over previous subunits. By eliminating the need to furcate the ribbons, workers installing the cables will be able to save significant time and labor. The improved flexibility at room temperatures, and colder, also reduces the likelihood of subunit jackets cracking when routing the subunits into an enclosure or splice cabinet in the field, and the adherence to safety regulations is requiring Applicant to use materials that are not typically used for as subunit jackets. The embodiments described herein allow for a wide range of installation and operation temperatures and reduce the likelihood of failures by allowing for the subunits and the ribbons within them to more easily move to low stress positions. 
       FIG.  1    and  FIG.  2    depict an optical fiber cable, shown as ribbon cable  10 , according to an exemplary embodiment. The ribbon cable  10  includes a cable jacket  12  having an inner surface  14  and an outer surface  16 . The inner surface  14  defines a central bore  18 , and the outer surface  16  defines an outermost extent of the ribbon cable  10 . In embodiments, the outer surface  16  defines an outer diameter of the ribbon cable  10  from 20 mm to 40 mm. While the term “diameter” is used, the outer surface  16  may not define a circle, and in such instances, “diameter” refers to the largest cross-sectional outer dimension of the ribbon cable  10 . Further, in embodiments, the inner surface  14  and the outer surface  16  define a thickness of the cable jacket  12  from 1 mm to 10 mm, more particularly from 2 mm to 5 mm. 
     Disposed within the central bore  18  are a plurality of subunits  20 . In various embodiments, the subunits  20  are helically wound (e.g., wound around each other, wound around one or more central strength element), which facilitates bending and coiling of the ribbon cable  10 , e.g., enhancing the routability of the ribbon cable  10 . 
     Referring to  FIG.  2   , one subunit  20  is shown in detail, while the remaining subunits  20  are shown schematically. As can be seen, the subunit  20  includes a plurality of ribbons  22 . Each ribbon  22  includes a plurality of optical fibers  24  in a planar configuration. The optical fibers  24  may be held in the planar configuration using a ribbon matrix material. 
     The cable jacket  12  includes a plurality of strengthening members, shown as strengthening yarns  38 , contained within the material of the cable jacket  12  between the inner surface  14  and the outer surface  16 . In an embodiment, the ribbon cable  10  includes four strengthening yarns  38  disposed within the cable jacket  12  in two pairs that are equidistantly spaced around the cable jacket  12 . In embodiments, the strengthening yarns  38  are textile yarns. Exemplary textile yarns suitable for use as the strengthening yarns include at least one of glass fibers, aramid fibers, cotton fibers, or carbon fibers, among others. 
     In various embodiments, jacket  12  is formed from a polymer material and in specific embodiments is formed from a polyolefin material. Exemplary polyolefins suitable for use in the jacket  12  include one or more of medium-density polyethylene (MDPE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and/or polypropylene (PP), amongst others. Exemplary thermoplastic elastomers suitable for use in the jacket  12  include one or more of ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM), ethylene-octene (EO), ethylene-hexene (EH), ethylene-butene (EB), ethylene-vinyl acetate (EVA), and/or styrene-ethylene-butadiene-styrene (SEBS), amongst others. 
     In various embodiments, the cable jacket  12  includes an access feature  40 , such as a ripcord or strip of polymer material that is dissimilar from the material of the cable jacket  12  (e.g., polypropylene strip in a predominantly polyethylene jacket). In embodiments, the ripcord is a yarn that includes at least one of a textile fiber (such as those listed above), liquid crystal polymer fibers, or PET polyester fibers, among others. In one embodiment, the ribbon cable  10  includes two access features  40  that are arranged diametrically within the cable jacket  12 . In other embodiments, the ribbon cable  10  may include a single access feature  40  or more than two access features  40 , such as up to four access features  40 . The access features  40  may be positioned such that strengthening yarns  38  are evenly spaced around the access feature  40 . 
     In the embodiment depicted in  FIG.  1   , a water barrier layer  32  is located within jacket  12  and surrounds subunits  20 . Water barrier layer  32  absorbs water which in turn prevents or limits water from traveling along cable  10  and/or from contacting the subunits  20 . In embodiments, the water barrier layer  32  is a water-blocking tape, e.g., that absorbs water and/or swells when contacted with water. In other embodiments, the water barrier layer  32  is an SAP powder applied to the exterior of the subunits  20  and/or the inner surface  14  of the cable jacket  12 . As used herein, all of the components from the water barrier layer  32  inward are referred to as the cable core  33 . 
       FIG.  3    depicts an embodiment of optical fiber subunit, shown as a subunit  20 . Subunit  20  includes jacket  26  surrounding a plurality of optical fibers, shown as optical fibers  24 . In specific embodiments, each subunit includes one or more access features, shown as rip cords  28 . Rip cords  28  are arranged at different locations within jacket  26 , such as being diametrically opposed to each other. In another embodiment, two or more rip cords  28  are located at the same and/or nearly the same location (e.g., such that the two or more rip cords  28  at the same location interface against each other along the length of jacket  26 ). 
     In various embodiments, jacket  26  includes a first polymer composition comprising a low smoke, zero halogen (LSZH) material. In a specific embodiment, the first polymer composition that forms jacket  26  has a storage modulus of no more than 500 MPa at room temperature (e.g., about 20° C.) and no more than 4000 MPa at −20 (negative twenty) ° C., or more specifically no more than 200 MPa at room temperature and no more than 2000 MPa at −20 (negative twenty) ° C. In one embodiment, subunit jacket has a thickness between 0.15 mm and 0.45 mm, and more specifically between 0.2 mm and 0.35 mm. Applicant has determined that most low smoke, zero halogen materials that are too brittle and inflexible to provide easy to use, routable subunits. However, Applicant has identified LSZH materials with these storage modulus ranges and/or thickness ranges, allows for use of LSZH materials while still providing for a routable subunit that is resistant to cracking. 
     In embodiments, the subunit jacket  26  comprises a low smoke, zero halogen (LSZH) and/or flame retardant, non-corrosive (FRNC) composition. In certain embodiments, the subunit jacket  26  is comprised of a flame retardant additive dispersed, mixed, or otherwise distributed in a polymeric resin. In embodiments, the polymeric resin is a thermoplastic, and in a more specific embodiment, the thermoplastic is a polyolefin-based resin. Polymer resins that may be used for the subunit jacket  26  include a single polymer or a blend of polymers selected from the following non-limiting list: ethylene-vinyl acetate copolymers, ethylene-acrylate copolymers, ethylene homopolymers (including but not limited to low density, medium density, and high density), linear low density polyethylene, very low density polyethylene, polyolefin elastomer copolymer, propylene homopolymer, polyethylene-polypropylene copolymer, butene- and octene branched copolymers, polyester copolymers, polyethylene terephthalates, polybutylene therephthalates, other polymeric terephthalates, and maleic anhydride-grafted versions of the polymers listed herein. In embodiments, the subunit jacket  26  includes at least one flame retardant additive. Exemplary flame retardant additives include aluminum trihydrate (ATH), magnesium hydroxide (MDH), ammonium polyphosphate (APP), pentaerythritol (PER), antimony oxides, zinc borates, boehmite, intumescent materials, and red phosphorous, among others. 
     In various embodiments, the subunit jacket  26  is formed from a first polymer material, and jacket  12  of cable  10  is formed from a different material. In one such embodiment, subunit jacket  26  is formed from a first LSZH halogen material, and jacket  12  is formed from a different LSZH halogen material. 
     In a specific embodiment, subunit jacket  26  has a limiting oxygen index (LOI) of 25 or greater (as measured according to ASTM D 2863 A) and/or a Peak Heat Release Rate (PHRR) of 300 kW/m 2  or less. In a more specific embodiment, subunit jacket  26  has an LOI of 30 or more and/or a PHRR of 250 kW/m 2  or less. 
     Referring to  FIG.  4   , a graph showing the storage modulus of various potential subunit jacket materials vs. temperature are show. The plot labeled “Low temp low modulus LSZH” illustrates the storage modulus of a specific LSZH material that Applicant has identified as being particularly suitable for subunit jacket  26 . In a specific embodiment, the “Low temp low modulus LSZH” of  FIG.  4    is lower than 200 MPa at 0° C. The plot labeled “Lower modulus LSZH” illustrates the storage modulus of another specific LSZH material that Applicant has identified as being particularly suitable for subunit jacket  26 . In a specific embodiment, the “Lower modulus LSZH” of  FIG.  4    is less than 500 MPa at 0° C. As shown in  FIG.  4   , both the Low temp low modulus LSZH material and the Lower modulus LSZH have storage moduli over the temperature similar to PVC while providing the benefits of a LSZH material. Further, as compared to the “Current LSZH” material, both the Low temp low modulus LSZH material and the Lower modulus LSZH have much lower storage moduli representing the better flexibility and routability provided by these materials. 
     Referring to  FIG.  5    and  FIG.  6   , ribbon cable  110  and ribbon cable  210  are shown, respectively, according to exemplary embodiments. Ribbon cable  110  and ribbon cable  210  are substantially the same as ribbon cable  10 , except for the differences discussed herein. In general,  FIG.  5    and  FIG.  6    depict the effect of the level of air pressure/vacuum and different materials within the subunit jackets on subunit jacket structure and performance. 
     Referring to  FIG.  5   , ribbon cable  110  includes jacket  112  defining a central core in which subunits  120  are located. Subunits  120  include subunit jackets  126 , which are formed from a polyvinylchloride (PVC) material around optical fibers  24 . In  FIG.  5   , subunit jacket  126  was formed around optical fibers  24  with reduced air pressure (e.g., a vacuum) within subunit jacket  126  (e.g., in the region between subunit jacket  126  and optical fibers  24 ). In  FIG.  6   , ribbon cable  210  includes jacket  212  defining a central core in which subunits  220  are located. Subunits  220  include subunit jackets  226 , which are formed around optical fibers  24  from the material identified as “Current LSZH” in  FIG.  4   . In  FIG.  6   , subunit jacket  226  was formed around optical fibers  24  with ambient atmospheric air pressure between subunit jacket  126  and optical fibers  24 . As a result, subunit jacket  226  in  FIG.  6    is less tightly formed around optical fibers  24  than subunit jacket  126  in  FIG.  5   . 
     Referring to Table 1 below, a table demonstrating the effect of the level of air pressure within a subunit jacket on signal attenuation is shown. 
     
       
         
           
               
               
               
             
               
                   
                   
               
               
                   
                 Vacuum 
                 Average 
               
               
                   
                 Setpoint 
                 attenuation 
               
               
                   
                   
               
             
            
               
                   
                 No vacuum 
                 0.33 db/km 
               
               
                   
                 Vacuum on 
                 0.65 db/km 
               
               
                   
                 Air Insertion 
                  0.4 db/km 
               
               
                   
                   
               
            
           
         
       
     
     As shown in Table 1, Applicant has observed that creating a vacuum or increasing pressure between the subunit jacket and the optical fibers while forming the subunit jacket may negatively affect the signal attenuation of the subunit. As indicated in  FIG.  7   , when the subunit jacket is formed around a plurality of optical fibers with unaltered atmospheric pressure (e.g., within 5% of one atmosphere) between the subunit jacket and the optical fibers, the signal attenuation of the subunit is 0.33 db/km. When the subunit jacket is formed around a plurality of optical fibers with a vacuum created between the subunit jacket and the optical fibers, the signal attenuation of the subunit is 0.65 db/km. When the subunit jacket is formed around a plurality of optical fibers while air is inserted between the subunit jacket and the optical fibers, the signal attenuation of the subunit is 0.4 db/km. Applicant has observed there is a balance between providing sufficient mobility for the ribbons to relieve stress while providing enough restraint to prevent the ribbons from moving significantly out of the stack, which may also result in attenuation. 
     Referring to  FIG.  7   , a method  300  of forming an optical cable, such as optical ribbon cable  10  is shown. According to one method of producing cable  10 , a first optical fiber  24  is unspooled from a spool (step  310 ). A first polymer composition is extruded to form a first subunit jacket  26  around the optical fibers  24  (step  320 ). A second optical fiber  24  is unspooled from a spool (step  330 ), and the first polymer composition is extruded to form a second subunit jacket  26  around the second optical fiber  24  (step  340 ). A second polymer composition is extruded around the first subunit jacket  26  and the second subunit jacket  26  to form an outer jacket. In a specific embodiment, subunit jacket  26  has a drawdown ratio of 4 or less, and more specifically subunit jacket  26  has a drawdown ratio of 3.5 or less, and more specifically subunit jacket  26  has a drawdown ratio less than 2.0, and even more specifically has a drawdown ratio of around 1.5. Described another way, subunit jacket  26  has an elongation break point of at least 140% at room temperature (as measured according to IEC 811-1-1). 
     Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more than one component or element, and is not intended to be construed as meaning only one. 
     It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the disclosed embodiments. Since modifications, combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the embodiments may occur to persons skilled in the art, the disclosed embodiments should be construed to include everything within the scope of the appended claims and their equivalents.