Patent Abstract:
A telecommunications cable includes a distribution cable, a tether branching from the distribution cable at a breakout location, and an enclosure that surrounds the breakout location. The enclosure is secured to the distribution cable at first and second adhesion regions. The enclosure can also secure to the tether at a third adhesion region. The adhesion regions are treated by sanding the regions, cleaning the regions, and then plasma-etching the regions immediately before welding/injection molding the enclosure around the breakout location.

Full Description:
TECHNICAL FIELD 
       [0001]    The principles disclosed herein relate to fiber optic cable systems. More particularly, the present disclosure relates to fiber optic cable systems having breakout arrangements protecting branch cables broken out from main cables. 
       BACKGROUND 
       [0002]    Passive optical networks are becoming prevalent in part because service providers want to deliver high bandwidth communication capabilities to customers. Passive optical networks are a desirable choice for delivering high-speed communication data because they may not employ active electronic devices, such as amplifiers and repeaters, between a central office and a subscriber termination. The absence of active electronic devices may decrease network complexity and/or cost and may increase network reliability. 
         [0003]      FIG. 1  illustrates a network  100  deploying passive fiber optic lines. As shown in  FIG. 1 , the network  100  may include a central office  110  that connects a number of end subscribers  115  (also called end users  115  herein) in a network. The central office  110  may additionally connect to a larger network such as the Internet (not shown) and a public switched telephone network (PSTN). The network  100  may also include fiber distribution hubs (FDHs)  130  having one or more optical splitters (e.g., 1-to-8 splitters, 1-to-16 splitters, or 1-to-32 splitters) that generate a number of individual fibers that may lead to the premises of an end user  115 . The various lines of the network can be aerial or housed within underground conduits (e.g., see conduit  105 ). 
         [0004]    The portion of network  100  that is closest to central office  110  is generally referred to as the F 1  region, where F 1  is the “feeder fiber” from the central office. The F 1  portion of the network may include a distribution cable having on the order of 12 to 48 fibers; however, alternative implementations may include fewer or more fibers. The portion of network  100  that includes an FDH  130  and a number of end users  115  may be referred to as an F 2  portion of network  100 . Splitters used in an FDH  130  may accept a feeder cable having a number of fibers and may split those incoming fibers into, for example,  216  to  432  individual distribution fibers that may be associated with a like number of end user locations. 
         [0005]    Referring to  FIG. 1 , the network  100  includes a plurality of breakout locations  125  at which branch cables (e.g., drop cables, stub cables, etc.) are separated out from main cables (e.g., distribution cables). Breakout locations can also be referred to as tap locations or branch locations and branch cables can also be referred to as breakout cables. At a breakout location, fibers of the branch cables are typically spliced to selected fibers of the main cable. However, for certain applications, the interface between the fibers of the main cable and the fibers of the branch cables can be connectorized. 
         [0006]    Stub cables are typically branch cables that are routed from breakout locations to intermediate access locations such as a pedestals, drop terminals or hubs. Intermediate access locations can provide connector interfaces located between breakout locations and subscriber locations. A drop cable is a cable that typically forms the last leg to a subscriber location. For example, drop cables are routed from intermediate access locations to subscriber locations. Drop cables can also be routed directly from breakout locations to subscriber locations hereby bypassing any intermediate access locations 
         [0007]    Branch cables can manually be separated out from a main cable in the field using field splices. Field splices are typically housed within sealed splice enclosures. Manual splicing in the field is time consuming and expensive. 
         [0008]    As an alternative to manual splicing in the field, pre-terminated cable systems have been developed. Pre-terminated cable systems include factory integrated breakout locations manufactured at predetermined positions along the length of a main cable (e.g., see U.S. Pat. Nos. 4,961,623; 5,125,060; and 5,210,812). However, the installation of pre-terminated cables can be difficult. For example, for underground applications, pre-terminations can complicate passing pre-terminated cable through the underground conduit typically used to hold fiber optic cable (e.g., 1.25 inch inner diameter conduit). Similarly, for aerial applications, pre-terminations can complicate passing pre-terminated cable through aerial cable retention loops. 
       SUMMARY 
       [0009]    Certain aspects of the disclosure relate to a breakout process for pre-terminating branch cables to fiber optic distribution cables. 
         [0010]    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 
         [0011]      FIG. 1  shows a prior art passive fiber optic network; 
           [0012]      FIG. 2  is a side view of a tether branching from a distribution cable; 
           [0013]      FIG. 3  is a cross sectional view of an example distribution cable; 
           [0014]      FIG. 4  is a cross sectional view of an example tether; 
           [0015]      FIG. 5  is a perspective view of an example breakout assembly installed on a distribution cable at breakout location; 
           [0016]      FIG. 6  is a perspective view of an example retention block used at the breakout location of  FIG. 5 ; 
           [0017]      FIG. 7  shows an initial preparation of the distribution cable at the breakout location of  FIG. 5 ; 
           [0018]      FIG. 8  shows a first preparation step for a tether used at the breakout location of  FIG. 5 ; 
           [0019]      FIG. 9  shows a subsequent preparation step for the tether of  FIG. 8 ; 
           [0020]      FIG. 10  is a side view of an enclosure installed at breakout location according to one embodiment of the present disclosure; 
           [0021]      FIG. 11  is a top view of the enclosure of  FIG. 10 ; 
           [0022]      FIG. 12  is a flowchart illustrating an example installation process for installing an enclosure over a breakout assembly according to one embodiment of the present disclosure; 
           [0023]      FIG. 13  is a schematic view of a telecommunications cable including a tether branching from a distribution cable. 
           [0024]      FIG. 14  is a flowchart illustrating an example treatment process for preparing a cable to bond with an enclosure body according to one embodiment of the present disclosure; and 
           [0025]      FIG. 15  is a schematic diagram showing respective movement of a cable relative to a plasma etcher during the treatment process of  FIG. 14 ; 
           [0026]      FIG. 16  is a flow chart illustrating an example overmolding process for forming the enclosure body according to one embodiment of the present disclosure; 
           [0027]      FIG. 17  is a cross-sectional, schematic view depicting a distribution cable and tether placed within molds during the overmolding process of  FIG. 16 ; and 
           [0028]      FIG. 18  is a schematic diagram depicting an enclosure overmolded over a breakout location on a distribution cable of  FIG. 17 . 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    The present disclosure relates to mid-span breakout arrangements provided on distribution cables and methods for providing the breakout arrangements. Each breakout arrangement is provided at a breakout location to protect the optical coupling of a tether (i.e., a branch cable) to a distribution cable. 
         [0030]    Referring now to the figures in general, a typical breakout location  260  is provided at an intermediate point along the length of a distribution cable  220  (e.g., see  FIG. 2 ). At the breakout location  260 , a fiber  224   t  of a tether  240  is optically coupled to a fiber  224   dc  of the distribution cable  220  at a coupling location  205 . An enclosure  300  (e.g., an overmold) is typically provided around the distribution cable  220  and the tether  240  at the breakout location  260  to protect the optical fibers  224 . 
         [0031]      FIG. 3  shows an example distribution cable  220  including six separate buffer tubes  222  each containing twelve fibers  224   dc . The buffer tubes  222  may be gel filled. The distribution cable  220  also includes a central strength member  226  for reinforcing the cable  220 , and an outer strength layer/member  228 , such as aramid fiber/yarn (e.g., Kevlar® fiber), also for reinforcing the cable. The distribution cable  220  further includes an outer jacket  230  that encloses the buffer tubes  222 . Ripcords  232  can be provided for facilitating tearing away portions of the jacket  230  to access the fibers  224   dc  within the jacket  230 . A typical distribution cable includes a relatively large number of fibers (e.g., 72, 144 or more fibers). The fibers are typically segregated into separate groups with each group contained within a separate buffer tube. The fibers within each buffer tube can include either ribbon fibers or loose fibers. 
         [0032]    The various aspects of the present disclosure are also applicable to distribution cables having fewer numbers of fibers (e.g., two or more fibers). For example, the distribution cable can include an outer jacket enclosing a single buffer tube and at least two strength members extending on opposite sides of the single buffer tube (not shown). An outer strength layer/member, such as aramid fiber/yarn, can surround the single buffer tube within the jacket. The single buffer tube can enclose loose fibers or ribbon fibers. 
         [0033]      FIG. 4  illustrates an example tether  240  configured to join to the distribution cable  220  at the breakout location  260 . The tether  240  includes a central buffer tube  242  containing multiple fibers  224   t  (e.g., typically one to twelve loose or ribbonized fibers). Strength members  246  (e.g., flexible rods formed by glass fiber reinforced epoxy) are positioned on opposite sides of the central buffer tube  242 . An outer jacket  250  surrounds the strength members  246  and the buffer tube  242 . An additional strength layer  248  (e.g., aramid fiber/yarn) can be positioned between the buffer tube  242  and the outer jacket  250 . In the example shown, the tether  240  is depicted as having a flat cable configuration. The outer jacket  250  includes an outer perimeter having an elongated transverse cross-sectional shape. The transverse cross-sectional shape includes oppositely positioned, generally parallel sides  252  interconnected by rounded ends  254 . However, any suitable cable configuration can be utilized for both the distribution cable and the tether cable. 
         [0034]    Referring now to  FIG. 5 , one or more tether fibers (e.g., typically less than twelve fibers)  224   t  are preferably optically coupled (e.g., spliced) at a coupling location  205  to selected fibers  224   dc  of the distribution cable  220  extending from one of the exposed buffer tubes  222 . For clarity, only a single tether fiber  224   t , and distribution cable fiber  224   dc  are shown coupled together in the figures. The opposite ends of the tether fibers  224   t  are configured to optically couple to a drop terminal or other type of telecommunications equipment (not shown) offset from the breakout location  260 . For example, the tether  240  can terminate in one or more fiber optic connectors (not shown). 
         [0035]    A breakout assembly  200  having features that are examples of inventive aspects in accordance with the principles of the present disclosure is shown installed on a distribution cable in  FIG. 5 . The breakout assembly  200  includes a sleeve  202  mounted over the optical fibers  224   t ,  224   dc  at the coupling location  205 . An optional protective tube  280  can also be provided over the fibers  224   t ,  224   dc  and the sleeve  202 . An enclosure  300  surrounds the coupled optical fibers  224   dc ,  224   t , the sleeve  202 , the optional tube  280 , and the exposed buffer tubes  222  of the distribution cable  220 . 
         [0036]    In general, the enclosure  300  has a body  310  that protects the optical connection between the tether  240  and the distribution cable  220 . One end  302  of a body  310  of the enclosure  300  extends over the distribution cable  220  adjacent a first end  352  of the stripped region  350  and the other end  304  of the body  310  extends over the tether cable  240  and the distribution cable  220  adjacent a second end  354  of the stripped region  350 . The tether  240  generally extends outwardly a length from the enclosure  300  to a connection end  256 . The enclosure  300  can include an overmold. 
         [0037]    When the tether  240  is secured to the distribution cable  220 , the tether  240  should preferably be able to withstand a pullout force of at least one hundred pounds. To meet this pullout force requirement, the breakout assembly  200  also can includes a retention block  270  (see  FIG. 6 ) configured to strengthen the mechanical interface between the tether  240  and the distribution cable  220 . Typically, the retention block  270  is enclosed within the protective enclosure  300 . 
         [0038]    As shown at  FIG. 6 , the retention block  270  includes a base  274  and a cover  272  between which the fiber  224   t  of the tether  240  extends. First and second protrusions  276 ,  278  extend from the cover  272  and base  274 , respectively. In one embodiment, the retention block  270  has a polycarbonate construction. Further details regarding the retention block  270  can be found in U.S. provisional application Ser. No. 60/781,280, filed Mar. 9, 2006, and entitled “FIBER OPTIC CABLE BREAKOUT CONFIGURATION,” the disclosure of which is hereby incorporated by reference. 
         [0039]    It is preferred for the fibers  224   t  of the tether to be pre-terminated to the fibers  224   dc  of the distribution cable. “Pre-terminated” means that the tether fibers  224   t  are fused or otherwise connected to the fibers  224   dc  of the distribution cable  220  at the factory as part of the cable manufacturing process rather than being field terminated. The remainder of the breakout assembly  200  is also preferably factory installed. 
         [0040]    Referring to  FIGS. 7-9 , to prepare the breakout location  260  on the distribution cable  220 , a portion of the outer jacket  230  is first stripped away to provide a stripped region  350  ( FIG. 7 ). In certain embodiments, portions of a cable netting can be removed adjacent the first and second ends  352 ,  354 , respectively, so that the buffer tubes  222  are exposed ( FIG. 7 ). The outer strength layer/member  228  also can be displaced (e.g., bunched at one side of the cable  220 ) adjacent the ends  352 ,  354  to facilitate accessing the buffer tubes  222  (see, e.g.,  FIG. 5 ). Tape can be used to prevent the intermediate length of netting that remains at the breakout location  260  from unraveling ( FIG. 7 ). 
         [0041]    One of the buffer tubes  222  is selected and a first window  358  is cut into the selected buffer tube  222  adjacent the first end  352  of the stripped region  350  and a second window  360  is cut into the selected buffer tube  222  adjacent the second end  354  of the stripped region  350  ( FIG. 7 ). The fibers  224   dc  desired to be broken out are accessed and severed at the second window  360 . After the fibers  224   dc  have been severed, the fibers  224   dc  are pulled from the buffer tube  222  through the first window  358 . With the distribution cable  220  prepared as shown in  FIG. 7 , the fibers  224   dc  are ready to be terminated to one or more fibers  224   t  of a prepared tether  240 . 
         [0042]    To prepare the tether  240  to be installed on the prepared distribution cable  220 , a portion of the outer jacket  250  is stripped away to expose the central buffer tube  242  and the strength members  246  (see  FIG. 8 ). As shown at  FIG. 8 , the central buffer tube  242  and the strength members  246  project outwardly beyond an end  247  of the outer jacket  250 . The strength layer  248  ( FIG. 4 ) is removed from around the buffer tube  242 . After removing the end portion of the outer jacket  250 , the strength members  246  are trimmed as shown at  FIG. 8 , and an end portion of the central buffer tube  242  is removed to expose the fibers  224   t  ( FIG. 9 ). 
         [0043]    To connect the tether fibers  224   t  to the distribution cable fibers  224   dc , the sleeve  202  ( FIG. 5 ) is first slid over the fibers  224   t  of the tether. In certain embodiments, the sleeve  202  can be slid up over the buffer tube  242  of the tether  240 . The optional protective tube  280  ( FIG. 5 ) also can be slid over the tether  240 . When the sleeve  202  and protective tube  280  are mounted on the tether  240 , the fibers  224   t  of the tether  240  are coupled (e.g., fused) to the fibers  224   dc  of the distribution cable  220 . After the coupling process is complete, the sleeve  202  can be slid over the coupling location  205  to protect the fused fibers  224   t ,  224   dc . The tube  280  can be slid over the sleeve  202 . The fibers are then tested to confirm that the fibers meet minimum insertion loss requirements. 
         [0044]    If desired, the tether  240  can be mounted to the retention block  270 . For example, as shown at  FIG. 9 , the strength members  246  can be positioned within side grooves  273  on the base  274  of the retention block  270 , and the central buffer tube  242  can be inserted within a central groove  275  on the base  274 . In the example illustrated, the central buffer tube  242  has a length that extends beyond a first end of the base  274 , and the strength members  246  have lengths that terminate generally at the first end of the base  274 . After securing the retention block  270  to the distribution cable  220 , one end of the optional protective tube  280  can be mounted over the protrusions  276 ,  278  of the retention block  270  (see  FIG. 5 ). 
         [0045]    After verifying insertion loss, heat resistant tape is wrapped around the distribution cable  220 , the tether  240 , and the breakout location assembly  200 . Thereafter, the enclosure  300  is applied over the taped breakout location  260  (see  FIGS. 10-11 ). The enclosure (e.g., an overmold layer)  300  seals and protects the underlying components of the breakout assembly  200 . The tether  240  extends outwardly from the body  310  of the enclosure  300  to tether connectors (not shown) spaced from the enclosure body  310 . 
         [0046]    Referring now to  FIG. 12 , the enclosure  300  is installed over the breakout assembly  200  by securing the ends  302 ,  304  of the enclosure body  310  to the distribution cable  220 . The ends  302 ,  304  of the enclosure body  310  also can be secured to the tether  240 .  FIG. 12  illustrates a flowchart depicting an installation process  1200  for installing the enclosure body  310 . The installation process  1200  begins at start module  1202  and proceeds to a first prepare operation  1204 . 
         [0047]    The first prepare operation  1204  provides protection for the exposed buffer tubes  222  and coupled optical fibers  224   dc ,  224   t  against the heat and other stresses associated with overmolding an enclosure. For example, heat resistant tape  208  ( FIG. 13 ) can be wrapped around the buffer tubes  222  and coupled optical fibers  224   dc ,  224   t . As shown in  FIG. 13 , the heat resistant tape  208  is wrapped from the distribution cable jacket  230  adjacent the first end  352  of the stripped region  350  ( FIG. 5 ), around the breakout assembly  200  ( FIG. 5 ), past the second end  354  of the stripped region  350 , and over the distribution cable jacket  230  and tether jacket  250  at the second end  354  of the stripped region  350  ( FIG. 5 ). 
         [0048]    A second prepare operation  1206  provides regions of adhesion on the distribution cable  220  to which the enclosure body  310  can be secured. The process for providing the adhesion regions will be discussed herein with reference to  FIGS. 14-17 . In general, the adhesion regions  322 ,  324  are provided on the outer jacket  230  of the distribution cable  220 . For example, as shown in  FIG. 13 , a first adhesion region  322  is typically provided on the distribution cable  220  adjacent the first end  352  of the stripped region  350  and a second adhesion region  324  is provided adjacent the second end  354  of the stripped region  350 . 
         [0049]    The adhesion regions  322 ,  324  have lengths L 1 , L 2 , respectively, that extend longitudinally along the distribution cable  220  ( FIG. 13 ). In the example shown in  FIG. 13 , the first adhesion region  322  extends from a first end of the heat resistant tape  208  in a first direction extending generally away from the breakout location  206  ( FIG. 5 ). The second adhesion region  324  extends from a second, opposite end of the tape  208  in a second, opposite direction generally away from the breakout location  206 . Typically, the lengths L 1 , L 2  of the adhesion regions  322 ,  324  extend about 1-4 inches, inclusive. Preferably, the lengths L 1 , L 2  each extend about 2-3 inches. 
         [0050]    An optional third prepare operation  1208  provides a region of adhesion on the tether  240  to which the enclosure body  310  also can be secured. For example, a third adhesion region  326  having a third length L 3  is shown in  FIG. 13  extending over the outer jacket  250  of the tether  240 . In general, the third prepare operation  1208  is substantially similar to the second prepare operation  1206 . The third adhesion region  326 , therefore, is generally similar to the adhesion regions  322 ,  324  provided on the distribution cable  220 . Typically, the length L 3  of the third adhesion region  326  is substantially the same as the lengths L 1 , L 2  of the adhesion regions  322 ,  324 , respectively, of the distribution cable  220 . 
         [0051]    An overmold operation  1210  installs the enclosure body  310  over the breakout location  206  ( FIG. 5 ) of the distribution cable  220 . In general, the enclosure  310  encloses the distribution cable  220  and the breakout assembly  200 . Typically, the enclosure  310  also encloses a portion of the tether  240 . In the example shown, the first end  302  of the enclosure body  310  is formed around the first adhesion region  352  and the second end  304  of the enclosure body  310  is formed around the second adhesion region  354  and the third adhesion region  356 . In some embodiments, the enclosure body  310  also can extend past the adhesion regions  352 ,  354 ,  356 . The overmold operation  1210  is described in more detail with respect to  FIG. 16 . 
         [0052]      FIG. 14  illustrates a flowchart depicting an example treatment process  1400  for providing enhanced adhesion between two materials, such as two polymeric materials. For example, the treatment process  1400  increases the adhesion between a polyurethane material and a polyethylene material. The treatment process  1400  can be used to prepare the outer jacket  230  of the distribution cable  220  to enable the enclosure body  310  to couple more securely to the outer jacket  230 . For example, in preliminary testing, the treatment process  1400  has increased the pull out strength of a polyethylene cable from a polyurethane enclosure by 300%-400%. Optionally, the outer jacket  250  of the tether  240  can be prepared using substantially the same process. 
         [0053]    The treatment process  1400  begins at start module  1402  and proceeds to a sand operation  1404 . The sand operation  1404  roughens the circumferential surface of the outer jacket  230  at the first and second adhesion regions  322 ,  324 . Generally, the outer jacket  230  along the regions  322 ,  324  is sanded with a grit ranging from about 40 to about 180, and more preferably ranging from about 60 to about 120. Preferably, the gritted material (e.g., sandpaper) is rubbed laterally across the cable  220 . However, the cable  220  alternatively could be sanded along the longitudinal length of the cable  220 . 
         [0054]    A clean operation  1406  applies a cleaning agent to the sanded areas and then removes the excess cleaning agent. For example, alcohol (e.g., isopropyl alcohol) can be applied to the roughened surfaces of the outer jacket  230 . The excess alcohol can be wiped away with a clean cloth. The clean operation  1406  can be performed anytime after the sand operation  1404 . 
         [0055]    An etch operation  1408  is performed after the clean operation  1404 . In general, the etch operation  1408  is performed while the outer jacket  230  is still clean. It is believed that dirt or other contaminants can shield the outer jacket  230  from the full effects of the etching. Typically, the etch operation  1408  is performed within four minutes of the clean operation  1406  to inhibit contamination of the jacket  230  (e.g., from the environment). Preferably, the etch operation  1408  is performed within two minutes when not in a clean room environment. 
         [0056]    The etch operation  1408  increases the surface area of the adhesion regions  322 ,  324  by providing disruptions on the outer jacket  230  along the cleaned and sanded regions  322 ,  324 . Typically, the etch operation  1408  is performed using a plasma etcher  400  ( FIG. 15 ). One example of a suitable plasma etcher is the Flume™ system from Plasmatreat North America, Inc. 
         [0057]    The plasma etcher  400  has at least a first head  402  ( FIG. 15 ). Each head  402  is configured to emit a beam of plasma. In some embodiments, the beam of plasma is emitted in a ringed configuration. In other embodiments, a beam emitting nozzle (not shown) on the head  402  is configured to rotate in a circular pattern. In still other embodiments, however, the beam of plasma can be emitted from the head  402  in any desired configuration. 
         [0058]    The cable  220  is positioned adjacent the first head  402  so that the plasma beam is directed at one of the adhesion regions  322 ,  324 . Typically, the adhesion regions  322 ,  324  extend over a length that is greater than the diameter/width of the plasma beam. For example, the length of the adhesion region  322  is preferably about three inches and the diameter/width of the plasma beam is typically about one inch. 
         [0059]    To etch the entire length of each adhesion region  322 ,  324 , therefore, the cable  220  is moved back and forth along the length of each adhesion region  322 ,  324  along a longitudinal axis M of the cable  220 . In some embodiments, to etch the entire circumference of each adhesion region  322 ,  324 , the cable  220  is rotated at least partially about the longitudinal axis M. When one side of the cable  220  has been etched, the cable  220  can be flipped about 180° so that the etcher head  402  faces the opposite side of the cable  220 . The etching operation  1408  can then be repeated for the opposite side. 
         [0060]    In other embodiments, however, the plasma etcher  400  has a first head  402  and a second, opposing head  404  as shown in  FIG. 15 . The cable  220  is positioned between the opposing heads  402 ,  404  so that the plasma beams emitted from the heads  402 ,  404  contact both sides of the cable  220 . If desired, the cable  220  can be moved along the longitudinal axis M as discussed above to increase the surface area with which the etcher  400  interacts. In addition, the cable  220  also can be rotated about the longitudinal axis M to etch the entire circumference of the cable  220 . The treatment process  1400  ends at stop module  1410 . 
         [0061]      FIG. 16  illustrates a flowchart depicting an example overmold process  1600  for overmolding a telecommunications cable. The overmold process  1600  is performed after the etch operation  1408  of the treatment process  1400 . In general, care is taken to avoid contacting the treated (e.g., etched) cables  220 ,  240  with human hands. Preferably, the overmold process  1600  is performed within four minutes of the etch operation  1408  to mitigate the chances of contaminating (e.g., touching) the treated cables  220 ,  240 . The overmold operation  1410  surrounds the distribution cable  220  at the breakout location  206  ( FIG. 5 ) and the adhesion regions  322 ,  324 ,  326  of the cable jackets  230 ,  250  with an enclosure  300 . 
         [0062]    The overmold process  1600  begins at start module  1602  and proceeds to a mount operation  1604 . In the mount operation  1604 , the treated distribution cable  220  is placed in a mold  370 . In the example shown in  FIG. 17 , the distribution cable  220  is placed within a mold  370  formed from a first member  372  and a second member  374 . Other suitable molds  370  can also be used. 
         [0063]    Polymeric material is introduced into the mold in inject operation  1606 . The polymeric material is injected from a source  376 , through a conduit  378 , and into the mold  370  to cover portions of the distribution cable  220  including the treated adhesion regions  322 ,  324 . Generally, the enclosure body  310  is formed of a different material than the outer jacket of the distribution cable  220 . Typically, the enclosure body  310  is formed of Polyurethane and the outer jacket of the distribution cable  220  is formed from Polyethylene. In some embodiments, a portion of the tether  240  is placed into the mold  370  with the distribution cable  220  and the polymeric material is injected around the treated region  326  of the tether cable jacket  250 . 
         [0064]    A cure operation  1608  allows the polymeric material to harden. For example, the cure operation  1608  can allow the polymeric material time to cool. A remove operation  1610  removes the distribution cable  220  from the mold  370 . The hardened polymeric material remains secured around the distribution cable  220  to form an enclosure body  310  ( FIG. 18 ). The overmold process  1600  ends at stop module  1612 . 
         [0065]    It is preferred for the enclosure body  310  to be sized with a cross sectional shape sufficient to allow the breakout location  260  to be readily passed through a one and one-half inch inner diameter conduit or a one and one-quarter inch diameter conduit. In certain embodiments, the breakout location  260  has a cross sectional area that can be passed through a one inch inner diameter conduit. 
         [0066]    The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.

Technology Classification (CPC): 1