Patent Description:
Optical fibers provide advantages over conventional communication lines. As compared with traditional wire-based networks, optical-fiber communication networks can transmit significantly more information at significantly higher speeds. The amount of data transmitted over optical-fiber cables is continuously increasing worldwide. This is especially so in data centers because of the expansion of cloud computing, which requires that data be received and transmitted in limited physical space. As such, there is an increasing demand for high-fiber-count and high-fiber-density optical cables. Moreover, there is persistent desire to reduce construction costs of access cable networks, making the reduction of optical-cable diameter and weight central to the use of existing facilities (e.g., underground ducts) to reduce installation costs. Another practical requirement is the ability to mass-fusion splice optical fibers to shorten the time required for connecting cables. This means that there are several - possibly conflicting - demands, such as decreasing optical-cable diameters, increasing optical-fiber density, and improving optical-cable workability. This is a serious and difficult challenge for optical-cable manufacturers. To achieve easy workability, optical-fiber ribbons can preferentially be mass-fusion spliced to simultaneously make multiple optical-fiber connections. Conventional optical-fiber ribbons have the disadvantage of rigidity, however, because of the application of a resin layer around the optical-fiber assembly to keep the optical fibers in a parallel plane. This rigidity limits the possibility of increasing fiber density in optical-fiber cables. lt is well known to connect two optical fibers end-to-end by fusion splicing with a laser, electric arc, or the like. The splicing usually includes preparing each optical-fiber's end portion by stripping the coatings (e.g., the outer secondary coating and inner primary coating) from each optical fiber's outer glass cladding and inner glass core, and precisely cleaving each optical fiber's outer glass cladding and inner glass core to yield a bare glass end to be spliced. Typically, the respective cleaved, bare glass ends are precisely aligned in a single-splice, fusion-splicing machine that joins the two optical fibers. The splice alignment and other accommodations help to minimize any attenuation at the splice and provide a strong connection between the spliced ends.

The single-splicing machine typically includes opposite holding mechanisms for respectively holding the optical fibers so that the cleaved, bare glass ends can be precisely aligned. To facilitate alignment, each holding mechanism (e.g., a single-fiber alignment chuck) can include a platform or tray defining a V-shaped groove for precisely retaining each optical fiber's cleaved, bare end portion. Additionally, each alignment chuck or holding mechanism can further include a portion for precisely securing each optical fiber's coated portion adjacent to the cleaved, bare end portion.

Similarly, it is well known to collectively splice two optical-fiber ribbons end-to-end by mass-fusion splicing. Each optical-fiber ribbon, for example, may include twelve optical fibers that are held together by adhesive material. Preparing each optical-fiber ribbon's end portion typically includes separating the constituent optical fibers' respective end portions and then preparing each optical fiber to yield bare glass end portions. For efficiency, the respective cleaved, bare glass ends are precisely aligned in a mass-fusion splicing machine that joins the respective optical fibers.

The mass-fusion splicing machine (e.g., a mass-fusion splicer) typically employs opposite holding mechanisms (e.g., alignment chucks) for respectively securing the optical fibers so that their cleaved, bare glass ends can be precisely aligned. To facilitate alignment, each alignment chuck or other holding mechanism can include a platform or tray respectively defining a plurality of V-shaped grooves (e.g., <NUM> grooves or <NUM> grooves) for precisely retaining each optical fiber's cleaved, bare end portion. Additionally, each alignment chuck or other holding mechanism can further include a part or a portion for precisely securing each optical fiber's coated portion adjacent to the cleaved, bare end portion.

Flexible optical-fiber ribbons yield increased optical-fiber density in optical-fiber cables. Mass splicing such flexible optical-fiber ribbons requires positioning the optical-fiber ribbons in alignment chucks of a mass-fusion splicing machine, but sometimes the adhesive bonds (e.g., elongated beads) may cause interference within the alignment chucks (e.g., the V-shaped grooves in the alignment chuck). For example, some commercially available alignment chucks (e.g., used in mass-fusion splicing machines) cannot readily accommodate flexible optical-fiber ribbons if the pitch of the adhesive-bead pattern is too short (e.g., less than about <NUM> millimeters), because of adhesive-bead interference in the alignment chucks' V-shaped grooves. Alternatively, if the pitch of the adhesive-bead pattern becomes too long, flexible optical-fiber ribbons can become very flexible and difficult to load into the alignment chucks. A solution requires applying tension to both ends of the optical-fiber ribbon and positioning the edge of the optical fiber at either end of the alignment chuck to achieve proper loading of the optical-fiber ribbon into the alignment chuck.

<CIT> discloses an optical fiber ribbon with alternating bonding material patterns.

The invention provides an optical-fiber ribbon having excellent flexibility, strength, and robustness to facilitate rolling or folding of the constituent optical fibers in the ribbon-width direction, according to the appended claims. The optical-fiber ribbon can be readily mass-fusion spliced to make multiple optical-fiber connections.

In one aspect, the present invention embraces an optical-fiber ribbon that facilitates mass-fusion splicing via a mass-fusion splicing machine. An exemplary optical-fiber ribbon includes intermittent or recurrent gaps along its longitudinal length in which substantially no bonding material is present across the width of the optical-fiber ribbon. These intermittent gaps without bonding material (e.g., adhesive-free gaps, areas, zones, or portions) help to reduce or eliminate bonding-material interference as the optical-fiber ribbon is positioned within an alignment chuck, which is used to secure an optical-fiber ribbon in during preparations for mass-fusion splicing.

An exemplary optical-fiber ribbon includes a plurality n of respectively adjacent optical fibers (e.g., twelve or more optical fibers, such as <NUM>-micron optical fibers or <NUM>-micron optical fibers) extending in a longitudinal direction and arranged in parallel to form an optical-fiber assembly having a width w extending crosswise to a longitudinal length of the optical-fiber assembly. The optical-fiber ribbon further includes bonding material on the optical-fiber assembly (e.g., deposited as an adhesive bead on a major surface of the optical-fiber assembly, such as its upper planar surface) adhesively bonding adjacent optical fibers in the optical-fiber assembly, the bonding material repeatedly forming alternating first and second bonding-material patterns across the optical-fiber assembly for a portion of its longitudinal length, wherein, in the same direction along the longitudinal length of the optical-fiber assembly: (i) the first bonding-material patterns extend across the optical-fiber assembly from a first outermost optical fiber in the optical-fiber assembly to an opposite second outermost optical fiber in the optical-fiber assembly, and the second bonding-material patterns extend across the optical-fiber from the second outermost optical fiber in the optical-fiber assembly to the opposite first outermost optical fiber in the optical-fiber assembly; (ii) the alternating first and second bonding-material patterns have respective mean lengths l<NUM> and /<NUM> as measured along the longitudinal length of the optical-fiber assembly; and (iii) the alternating first and second bonding-material patterns achieve recurring adhesive-free gaps in which no bonding material is present across the width w of the optical-fiber assembly for a portion of its longitudinal length, the adhesive-free gaps having a minimum length g as measured along the longitudinal length of the optical-fiber assembly, wherein g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤ /<NUM> and g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤ l<NUM>.

Exemplary optical-fiber ribbons have excellent flexibility, strength, and robustness to facilitate rolling or folding of the constituent optical fibers in the ribbon-width direction. In addition, exemplary optical-fiber ribbons can be mass-fusion spliced to make multiple optical-fiber connections, and individual optical fibers can be separated without damaging adjacent optical fibers. Each optical fiber typically includes, from its center to its periphery, a glass core, a glass cladding, and one or more coatings (e.g., a primary coating, a secondary coating, and an optional ink layer). As such, corresponding embodiments of the optical-fiber ribbon herein disclosed are applicable to the related method for making an optical-fiber ribbon, and vice versa.

The foregoing illustrative summary, other objectives and/or advantages of the present disclosure, and the manner in which the same are accomplished are further explained within the following detailed description and its accompanying drawings.

The present invention is described hereinafter with reference to the accompanying drawings in which embodiments of the present invention are shown and in which like reference numbers indicate the same or similar elements. The drawings are provided as examples, may be schematic, and may not be drawn to scale. The present inventive aspects may be embodied in many different forms and should not be construed as limited to the examples depicted in the drawings.

Various aspects and features are herein described with reference to the accompanying figures. Details are set forth to provide a thorough understanding of the present disclosure. It will be apparent, however, to those having ordinary skill in the art that the disclosed optical-fiber ribbons and methods for producing optical-fiber ribbons may be practiced or performed without some or all of these specific details. As another example, features disclosed as part of one embodiment can be used in another embodiment to yield a further embodiment. Sometimes well-known aspects are not described in detail to avoid unnecessarily obscuring the present disclosure.

As depicted in <FIG>, an exemplary optical-fiber ribbon <NUM> includes a plurality n of respectively adjacent optical fibers <NUM> (e.g., <NUM>, <NUM>, or <NUM> optical fibers, such as <NUM>-micron optical fibers or <NUM>-micron optical fibers) extending in a longitudinal direction and arranged in parallel to form an optical-fiber assembly <NUM>, which has a width w extending crosswise to a longitudinal length of the optical-fiber assembly <NUM>. The optical-fiber ribbon <NUM> further includes bonding material <NUM> on the optical-fiber assembly <NUM> (e.g., deposited as adhesive beads on a major surface of the optical-fiber assembly <NUM>, such as its upper planar surface) adhesively bonding adjacent optical fibers <NUM> in the optical-fiber assembly <NUM>, the bonding material <NUM> repeatedly forming alternating first and second bonding-material pattems <NUM>, <NUM> across the optical-fiber assembly <NUM> for a portion of its longitudinal length, wherein, in the same direction along the longitudinal length of the optical-fiber assembly <NUM>: (i) the first bonding-material patterns <NUM> extend across the optical-fiber assembly <NUM> from a first outermost optical fiber 11a in the optical-fiber assembly <NUM> to an opposite second outermost optical fiber 11b in the optical-fiber assembly <NUM>, and the second bonding-material patterns <NUM> extend across the optical-fiber from the second outermost optical fiber 11b in the optical-fiber assembly to the opposite first outermost optical fiber 11a in the optical-fiber assembly; (ii) the alternating first and second bonding-material patterns <NUM>, <NUM> have respective mean lengths /<NUM> and /<NUM> as measured along the longitudinal length of the optical-fiber assembly <NUM>; and (iii) the alternating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly, wherein g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤ /<NUM> and g ≥ <NUM> × (l<NUM> = n) if /<NUM> ≤ l<NUM>. Typically, each of the first bonding-material patterns <NUM> has essentially the same length /<NUM>, and each of the second bonding-material patterns <NUM> has essentially the same length l<NUM>, too (e.g., the first and second bonding-material patterns <NUM>, <NUM> each exhibit regular pattems).

As depicted in <FIG>, an exemplary optical-fiber assembly <NUM> includes a plurality of optical fibers <NUM> arranged side-by-side such that the optical fibers <NUM> are substantially parallel to one another (e.g., aligned within the optical-fiber assembly <NUM>). Each optical fiber <NUM> may be closely spaced or contiguous with an adjacent optical fiber <NUM> but typically should not cross over one another along the length of the optical-fiber assembly <NUM>. Optical fibers <NUM> usually include a component glass fiber <NUM> and one or more surrounding coating layers <NUM>. Those having ordinary skill in the art will understand the various kinds of primary coatings, secondary coatings, and ink layers, as well as the structures and thicknesses thereof. This application hereby cites commonly owned <CIT> for a Microbend-Resistant Optical Fiber and <CIT> for a Reduced-Diameter Optical Fiber.

The optical-fiber assembly <NUM> (and the resulting optical-fiber ribbon <NUM>) have a substantially planar (i.e., flattened) geometry that defines a relatively narrow height, a relatively wide width, and a substantially continuous length (e.g., over <NUM>,<NUM> meters, such as <NUM>,<NUM> meters or more). As used herein, an optical-fiber assembly <NUM> as depicted in <FIG> inherently defines an upper side (i.e., the top), a lower side (i.e., the bottom), a left edge, and a right edge. The respective upper and lower sides define the major surfaces of the optical-fiber assembly <NUM> (and the resulting optical-fiber ribbon <NUM>, such as shown in <FIG>). Those having ordinary skill in the art will appreciate that flipping the optical-fiber assembly <NUM> degrees over its major transverse axis will reverse the top and bottom, and so the terms can be used interchangeably herein depending on the frame of reference. Similarly, those having ordinary skill in the art will appreciate that yaw rotating the optical-fiber assembly <NUM> degrees will reverse the right edge and left edge, and so the terms can be used interchangeably herein depending on the frame of reference. Accordingly, as used herein, terms such as "first side" and "second, opposite side" refer to the respective upper and lower sides of the optical-fiber assembly <NUM> (and the resulting optical-fiber ribbon), or vice versa depending on the frame of reference.

As shown in <FIG>, the optical fibers <NUM> are arranged in parallel and respectively adjacent to each other in a plane. As such, the nominal width w of the optical-fiber assembly <NUM> reflects the number n and diameter d of the optical fibers (i.e., w ≈ n × d). Typically, each optical fiber has a substantially circular cross section, and all the optical fibers in an optical-fiber ribbon have substantially the same nominal diameter. In an exemplary embodiment, the width w of the optical-fiber assembly is between about <NUM> millimeters and <NUM> millimeters (e.g., between <NUM> millimeters and <NUM> millimeters). In practice, the optical fibers are substantially contiguous to one another, although some small gaps may exist between adjacent optical fibers. The width of the resulting optical-fiber ribbon corresponds to the width w of the optical-fiber assembly.

In an exemplary embodiment, each optical fiber has a diameter d of between <NUM> microns and <NUM> microns, more typically about <NUM> microns. Alternatively, the optical fibers may have a reduced diameter d, such as between about <NUM> microns and <NUM> microns. In an exemplary embodiment, the optical-fiber assembly includes between six and <NUM> optical fibers (including <NUM> and <NUM>), such as between twelve and <NUM> optical fibers (including <NUM> and <NUM>). For example, an exemplary optical-fiber ribbon formed of twelve (<NUM>) <NUM>-micron optical fibers yields a nominal width w of <NUM> microns (i.e., <NUM> millimeters). Similarly, an exemplary optical-fiber ribbon formed of twelve (<NUM>) <NUM>-micron reduced-diameter optical fibers yields a nominal width w of <NUM> microns (i.e., <NUM> millimeters), and an exemplary optical-fiber ribbon formed of twelve (<NUM>) <NUM>-micron reduced-diameter optical fibers yields a nominal width w of <NUM> microns (i.e., <NUM> millimeters). Accordingly, those having ordinary skill in the art will appreciate that, with respect to optical-fiber ribbon <NUM> and the optical-fiber assembly <NUM>, the figures schematically exaggerate the width relative to length, such as to illustrate the characteristics of the first and second bonding-material patterns <NUM>, <NUM>.

Typically, along the optical-fiber assembly <NUM> for a portion of its longitudinal length, each first bonding-material pattern <NUM> immediately follows a second bonding-material pattern <NUM>, and each second bonding-material pattern <NUM> immediately follows a first bonding-material pattern <NUM>. In this regard, pitch p is the length of the recurring pattern of bonding material (e.g., deposited adhesive beads) as applied to an optical-fiber assembly (e.g., the repeating length of the alternating first and second bonding-material patterns <NUM>, <NUM>). In contrast, the mean length l<NUM> of the first bonding-material patterns <NUM> and the mean length of the l<NUM> of the second bonding-material patterns <NUM> reflect longitudinal distances covered by arrangements of bonding material (e.g., an adhesive bead or beads) from the first outermost optical fiber 11a to the second outermost optical fiber 11b, or vice-versa (e.g., across one width w of the optical-fiber assembly). Exemplary optical-fiber ribbons have a pitch p between about 10w and 150w as normalized to the width w of the optical-fiber ribbon <NUM> (e.g., about 15w-100w, such as about 20w-80w or 25w-60w).

In typical embodiments of the optical-fiber ribbon, the alternating first and second bonding-material patterns <NUM>, <NUM> have about the same respective mean lengths l<NUM> and l<NUM> as measured along the longitudinal length of the optical-fiber assembly <NUM> (e.g., l<NUM> ≈ l<NUM>). In some embodiments, the mean length l<NUM> of the first bonding-material patterns <NUM> is inclusively between <NUM> percent and <NUM> percent of the mean length of the l<NUM> of the second bonding-material patterns <NUM>, or the mean length l<NUM> of the second bonding-material patterns <NUM> is inclusively between <NUM> percent and <NUM> percent of the mean length l<NUM> of the first bonding-material patterns <NUM>.

In other embodiments of the optical-fiber ribbon, the alternating first and second bonding-material patterns <NUM>, <NUM> have different mean lengths l<NUM> and l<NUM> as measured along the longitudinal length of the optical-fiber assembly <NUM>. In some embodiments, the mean length l<NUM> of the first bonding-material patterns is between <NUM> percent and <NUM> percent of the mean length l<NUM> of the second bonding-material patterns, or the mean length l<NUM> of the second bonding-material patterns is between <NUM> percent and <NUM> percent of the mean length l<NUM> of the first bonding-material patterns.

In another exemplary optical-fiber ribbon <NUM>, the altemating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly <NUM>, wherein g ≥ <NUM> × (l<NUM> = n) if l<NUM> ≤ l<NUM> and g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤ l<NUM>.

In yet another exemplary optical-fiber ribbon <NUM>, the alternating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly <NUM>, wherein g ≥ <NUM> × (l<NUM> = n) if l<NUM> ≤ l<NUM> and g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤ l<NUM>.

In yet another exemplary optical-fiber ribbon <NUM>, the alternating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly <NUM>, wherein g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤ l<NUM> and g ≥ <NUM> × (l<NUM> ÷ n) if l<NUM> ≤l<NUM>.

In yet another exemplary optical-fiber ribbon <NUM>, the optical-fiber assembly <NUM> includes at least four adjacent optical fibers <NUM> extending in a longitudinal direction and arranged in parallel (i.e., n ≥ <NUM>), and the alternating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly <NUM>, wherein g ≥ <NUM> × I<NUM> if l<NUM> ≤ l<NUM> and g ≥ <NUM> × l<NUM> if l<NUM> ≤ l<NUM>.

In yet another exemplary optical-fiber ribbon <NUM>, the optical-fiber assembly <NUM> includes at least six adjacent optical fibers <NUM> extending in a longitudinal direction and arranged in parallel (i.e., n ≥ <NUM>), and the alternating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly <NUM>, wherein g ≥ (l<NUM> + l<NUM>), such as g > (l<NUM> + l<NUM>).

In yet another exemplary optical-fiber ribbon <NUM>, the alternating first and second bonding-material patterns <NUM>, <NUM> achieve recurring adhesive-free gaps <NUM> in which no bonding material <NUM> is present across the width w of the optical-fiber assembly <NUM> for a portion of its longitudinal length, the adhesive-free gaps <NUM> having a minimum length g as measured along the longitudinal length of the optical-fiber assembly <NUM>, wherein g ≥ (l<NUM> + l<NUM>) × (n = (n-<NUM>)), such as wherein g > (l<NUM> + l<NUM>) × (n = (n-<NUM>)). All things being equal, the adhesive-free gaps <NUM> between successive first and second bonding-material patterns <NUM>, <NUM> ought to be somewhat greater if the respective patterns extend across the optical-fiber assembly <NUM> a lateral distance less than the optical-fiber assembly's full width w, such as to the respective interfaces of each outermost optical fiber 11a, 11b and its respective adjacent optical fiber (e.g., w - 2d).

In yet another exemplary optical-fiber ribbon <NUM>, in the same direction along the longitudinal length of the optical-fiber assembly <NUM>, the minimum length g of the adhesive-free gaps <NUM> is a first adhesive-free gap distance g<NUM>-<NUM> between adjacent, spaced ends of successive first and second bonding-material patterns <NUM>, <NUM>, whereby g = g<NUM>-<NUM>, wherein both the adjacent end of the first bonding-material pattern <NUM> and the adjacent end of the second bonding-material pattern <NUM> are located along the second outermost optical fiber 11b in the optical-fiber assembly <NUM>, wherein g<NUM>-<NUM> ≥ <NUM> × ((l<NUM> + l<NUM>) ÷ 2n) as measured along the longitudinal length of the optical-fiber assembly <NUM>. (This exemplary embodiment bases the minimum length g on the average of the mean lengths l<NUM> and l<NUM> of the first and second bonding-material patterns, <NUM>, <NUM>. ) <FIG> similarly depicts a second adhesive-free gap distance g<NUM>-<NUM> between adjacent, spaced ends of successive second and first bonding-material patterns <NUM>, <NUM>, wherein both the adjacent end of the second bonding-material pattern <NUM> and the adjacent end of the first bonding-material pattern <NUM> are located along the first outermost optical fiber 11a in the optical-fiber assembly <NUM>. In a related embodiment, in the same direction along the longitudinal length of the optical-fiber assembly <NUM>, the successive first and second bonding-material patterns <NUM>, <NUM> have opposite, adjacent ends located along the first outermost optical fiber 11a in the optical-fiber assembly <NUM> and are spaced apart by a separation distance d<NUM>-<NUM>, wherein d<NUM>-<NUM> ≈ g<NUM>-<NUM> + l<NUM> + l<NUM> as measured along the longitudinal length of the optical-fiber assembly.

As illustrated in <FIG>, the area between first and second bonding-material patterns sometimes defines a trapezoidal adhesive-free area <NUM> having a short base g<NUM>-<NUM> (e.g., a first adhesive-free gap distance) along the second outermost optical fiber 11b in the optical-fiber assembly <NUM> and a long base d<NUM>-<NUM> (e.g., a separation distance) located along the first outermost optical fiber 11a in the optical-fiber assembly <NUM>. With respect to the bonding patterns depicted in <FIG>, the separation distance d<NUM>-<NUM> is noticeably shorter than the pitch p (e.g., the repeating length of the alternating first and second bonding-material patterns <NUM>, <NUM>). In contrast, with respect to the bonding patterns depicted in <FIG>, the separation distance d<NUM>-<NUM> is nearly the pitch p (e.g., the repeating length of the alternating first and second bonding-material patterns <NUM>, <NUM>), such that d<NUM>-<NUM> ≈ p.

By way on non-limiting example with respect to representative <NUM>-optical-fiber ribbons, exemplary adhesive-free gaps have a minimum length g (as measured along the longitudinal length of the optical-fiber assembly) of at least <NUM> millimeters, such as at least <NUM> millimeters to accommodate conventional alignment chucks. Typically, exemplary adhesive-free gaps have a minimum length g between about <NUM> millimeters and <NUM> millimeters, such as between about <NUM> millimeters and <NUM> millimeters (e.g., <NUM>-<NUM> millimeters, such as about <NUM> millimeters).

With reference to <FIG>, an exemplary trapezoidal adhesive-free area <NUM> might have a short base g<NUM>-<NUM> (e.g., a first adhesive-free gap distance) of between about <NUM> millimeters and <NUM> millimeters (e.g., about <NUM>-<NUM> millimeters) and a long base d<NUM>-<NUM> (e.g., a separation distance) of between about <NUM> millimeters and <NUM> millimeters, such as between about <NUM> millimeters and <NUM> millimeters (e.g., about <NUM>-<NUM> millimeters). In other embodiments, the separation distance d<NUM>-<NUM> might exceed <NUM> millimeters, such as <NUM> millimeters to <NUM> millimeters (e.g., about <NUM> millimeters).

With reference to <FIG>, an exemplary trapezoidal adhesive-free area <NUM> might have a short base g<NUM>-<NUM> (e.g., a first adhesive-free gap distance) of between about <NUM> millimeters and <NUM> millimeters (e.g., about <NUM>-<NUM> millimeters) and a long base d<NUM>-<NUM> (e.g., a separation distance) of between about <NUM> millimeters and <NUM> millimeters (e.g., about <NUM>-<NUM> millimeters). Here, the long base d<NUM>-<NUM> (e.g., a separation distance) is approximately the pitch p (e.g., the repeating length of the alternating first and second bonding-material patterns <NUM>, <NUM>). In other embodiments, the separation distance d<NUM>-<NUM> might exceed <NUM> millimeters, such as <NUM> millimeters to <NUM> millimeters (e.g., about <NUM> millimeters).

<FIG> depict exemplary optical-fiber ribbons, such as can be formed from an exemplary optical-fiber assembly <NUM> as depicted in <FIG>, further including bonding material <NUM> repeatedly forming alternating first and second bonding-material patterns <NUM>, <NUM> across the optical-fiber assembly <NUM> for a portion of its longitudinal length (e.g., between the optical-fiber assembly's outermost optical fibers to adhesively bond corresponding adjacent optical fibers).

In an exemplary optical-fiber ribbon, along a longitudinal portion of the optical-fiber assembly <NUM>, each of the first bonding-material patterns <NUM> respectively comprises a continuous bead of bonding material <NUM> (e.g., respective continuous adhesive beads between the first outermost optical fiber 11a and the second outermost optical fiber 11b such as depicted in <FIG>). Similarly, in an exemplary optical-fiber ribbon, along a longitudinal portion of the optical-fiber assembly <NUM>, each of the second bonding-material patterns <NUM> respectively comprises a continuous bead of bonding material <NUM> (e.g., respective continuous adhesive beads between the second outermost optical fiber 11b and the first outermost optical fiber 11b such as partially depicted in <FIG>). In another exemplary embodiment, for the same portion of the optical-fiber assembly's longitudinal length, the alternating first and second bonding-material patterns that achieve recurring adhesive-free gaps having a minimum length g in which no bonding material is present across the width w of the optical-fiber assembly each respectively include only (e.g., consists of or consists essentially of) a continuous bead of bonding material.

In another exemplary optical-fiber ribbon, along a longitudinal portion of the optical-fiber assembly <NUM>, each of the first bonding-material patterns <NUM> respectively comprises a plurality of successive elongated rectilinear beads <NUM> arranged lengthwise along the optical-fiber assembly <NUM>, wherein the beads <NUM> are configured to form elongated bonds between adjacent optical fibers <NUM> in the optical-fiber assembly <NUM> (e.g., an arrangement of rectilinear adhesive beads between the first outermost optical fiber 11a and the second outermost optical fiber 11b such as depicted in <FIG>). Similarly, in an exemplary optical-fiber ribbon, along a longitudinal portion of the optical-fiber assembly <NUM>, each of the second bonding-material patterns <NUM> respectively comprises a plurality of successive elongated rectilinear beads <NUM> arranged lengthwise along the optical-fiber assembly <NUM>, wherein the beads <NUM> are configured to form elongated bonds between adjacent optical fibers <NUM> in the optical-fiber assembly <NUM> (e.g., an arrangement of rectilinear adhesive beads between the second outermost optical fiber 11b and the first outermost optical fiber 11a such as depicted in <FIG>). In another exemplary embodiment, for the same portion of the optical-fiber assembly's longitudinal length, the alternating first and second bonding-material patterns that achieve recurring adhesive-free gaps having a minimum length g in which no bonding material is present across the width w of the optical-fiber assembly each respectively include only (e.g., consists of or consists essentially of) a plurality of successive elongated rectilinear beads arranged lengthwise along the optical-fiber assembly, wherein the beads are configured to form elongated bonds between adjacent optical fibers in the optical-fiber assembly.

During manufacturing, the bonding material may be applied to the optical-fiber assembly as a continuous bead or as discontinuous beads, such as disclosed in commonly assigned <CIT>. As noted, for example, along a portion of the optical-fiber assembly's longitudinal length, the bonding material may be applied as a plurality of successive rectilinear beads arranged lengthwise along the optical-fiber assembly (e.g., the successive beads forming a stepwise pattern across the optical-fiber assembly), so that the adhesive beads are configured to form elongated bonds between adjacent optical fibers in the optical-fiber assembly.

An exemplary method for applying either a continuous bead of bonding material or discontinuous beads of bonding material to an optical-fiber assembly in a way that facilitates faster line speeds during the manufacturing of optical-fiber ribbons is disclosed in commonly assigned <CIT> for an Optical-Fiber Ribbon.

In another aspect, the invention embraces a method of producing an optical-fiber ribbon. As shown in the process schematic depicted in <FIG> (processing from right to left), a plurality n of optical fibers <NUM> (e.g., <NUM> or <NUM> reduced-diameter optical fibers) are arranged into a longitudinal optical-fiber assembly <NUM> having a width w extending crosswise to a longitudinal length of the optical-fiber assembly. For example, a plurality of optical fibers <NUM> are introduced (e.g., fed into a die <NUM>) to provide a longitudinal optical-fiber assembly <NUM> in which the plurality of optical fibers <NUM> are substantially parallel and respectively adjacent to each other. Typically, the longitudinal optical-fiber assembly <NUM> is a loose arrangement of substantially parallel optical fibers with no bonding between the optical fibers and having interstices or grooves between adjacent optical fibers. When employing an aggregating die <NUM> to align the optical fibers, the entry speed of the loose optical fibers is the same as the exit speed of the longitudinal optical-fiber assembly.

During processing, the longitudinal optical-fiber assembly <NUM> advances at linear velocity v, typically at a linear speed greater than <NUM> meters per minute (e.g., greater than <NUM> meters per minute, such as greater than <NUM> meters per minute). In some exemplary embodiments, the longitudinal optical-fiber assembly <NUM> advances at linear velocity v between <NUM> and <NUM> meters per minute (e.g., between about <NUM> and <NUM> meters per minute).

As the optical-fiber assembly <NUM> passes near (e.g., beneath) a dispenser unit <NUM> (or similar dispensing device), bonding material (e.g., a curable adhesive) is applied to the optical-fiber assembly <NUM> to adhesively bond adjacent optical fibers <NUM> in the optical-fiber assembly. For example, the bonding material may be dispensed as a continuous adhesive bead (or a plurality of discontinuous beads) via a dispensing nozzle <NUM> to a major surface of the optical-fiber assembly <NUM> (e.g., its upper planar surface). Typically, the dispenser <NUM> and/or the dispensing nozzle <NUM> apply bonding material to each optical fiber <NUM> in the optical-fiber assembly <NUM> to bond the optical-fibers <NUM> into an optical-fiber ribbon <NUM>.

Exemplary process embodiments, described herein, include applying bonding material to the optical-fiber assembly (e.g., a major surface, such as its upper planar surface) to adhesively bond adjacent optical fibers in the optical-fiber assembly, wherein the dispenser repeatedly moves an amplitude Ad measured crosswise to the longitudinal length of the optical-fiber assembly such that the dispenser's amplitude Ad exceeds the optical-fiber assembly's width w (e.g., an "overshooting" technique). Thereafter, the optical-fiber assembly with an adhesive bead is passed through a curing station <NUM> for curing the bonding material (e.g., a curable adhesive, such as curable ultraviolet (UV) resins).

In some exemplary process embodiments, the dispenser <NUM> and/or the dispensing nozzle <NUM> (or other dispensing device) oscillate in a direction transverse to the longitudinal direction (i.e., in the width direction) of the optical-fiber assembly, and the optical-fiber assembly moves in the longitudinal direction, such as via a reel <NUM>. The tip of the dispenser <NUM> (e.g., the dispensing nozzle <NUM>) may oscillate (e.g., vibrate) in a transverse direction at a high frequency, such as between about <NUM> and <NUM>. In an exemplary process embodiment, the dispensing nozzle <NUM> may deliver liquid bonding material in fine droplets to the advancing optical-fiber assembly <NUM>. Because of surface tension, the liquid bonding material - if provided in sufficient droplets at a sufficient frequency - will flow together to form adhesive beads (e.g., elongated beads).

In an exemplary process embodiment, the dispenser <NUM> and/or the dispensing nozzle <NUM> move crosswise substantially corresponding to the width w of the longitudinal optical-fiber assembly <NUM>. In this way, the bonding material is applied as an adhesive bead across at least one major surface of the optical-fiber assembly (e.g., in a pattern on the upper planar surface substantially across the width of the optical-fiber assembly). As will be understood by those having ordinary skill in the art, providing an adhesive bead "substantially across the width" of the optical-fiber assembly bonds adjacent optical fibers to yield an optical-fiber ribbon (e.g., the adhesive deposition patterns extend to the outermost opposite optical fibers in the optical-fiber assembly).

In a related process embodiment, the dispenser <NUM> and/or the dispensing nozzle <NUM> move crosswise substantially corresponding to the lateral distance (w - 2d) between the two outermost optical fibers. As will be understood by those having ordinary skill in the art, this lateral distance (w - 2d) is the separation between the outermost grooves in the optical-fiber assembly (e.g., as defined by the respective interfaces of each outermost optical fiber and its respective adjacent optical fiber). As used herein, terms like "substantially corresponding to the width" and "substantially corresponding to the lateral distance" refer to the movement of a dispensing nozzle and/or the corresponding adhesive deposition patterns, which typically extend to the outermost opposite optical fibers in the optical-fiber assembly (e.g., opposite edge portions of the optical-fiber assembly).

Typically, the adhesive beads bonding adjacent optical fibers in the optical-fiber assembly form a regular pattern (continuous or discontinuous) across the width of the optical-fiber assembly, such as a zigzag-like pattern, a sawtooth-like pattern, or a sinusoidal-like pattern having a peak-to-valley amplitude substantially between (i) the lateral distance between the two outermost optical fibers (w - 2d) and (ii) the width w of the optical-fiber assembly. (Some excess bonding material may be present outside one or both outermost optical fibers in the optical-fiber ribbon. ) In some exemplary process embodiments, the dispensing nozzle may pause when positioned above grooves in the optical-fiber assembly to deposit bonding material as longitudinal, rectilinear adhesive beads within the respective grooves (e.g., grooves between contiguous optical fibers).

In process embodiments in which the dispenser <NUM> and/or the dispenser nozzle <NUM> move crosswise substantially corresponding to the (i) the lateral distance between the two outermost optical fibers (w - 2d) and (ii) the width w of the optical-fiber assembly, the application of bonding material periodically or intermittently stops (e.g., while the longitudinal optical-fiber assembly continues to advance at linear velocity v) to achieve recurring adhesive-free gaps in which no bonding material is present across the width w of the optical-fiber assembly for a portion of its longitudinal length. In this way, the intermittent application of bonding material to the optical-fiber assembly achieves exemplary optical-fiber ribbons, such as those depicted in <FIG>.

In an alternative process embodiment, the dispenser <NUM> and/or the dispensing nozzle <NUM> move crosswise but "overshoot" the width w of the longitudinal optical-fiber assembly <NUM>. That is, the dispenser <NUM> and/or dispensing nozzle <NUM> move an amplitude Ad measured crosswise to the longitudinal length of the optical-fiber assembly <NUM>, wherein the dispenser's amplitude Ad exceeds the optical-fiber assembly's width w. In this way, the bonding material is applied as an adhesive bead <NUM> across at least one major surface of the optical-fiber assembly (e.g., in a pattern on the upper planar surface substantially across the width of the optical-fiber assembly) to bond adjacent optical fibers. The dispenser <NUM> and/or the dispensing nozzle <NUM> apply bonding material to each optical fiber <NUM> in the optical-fiber assembly <NUM> to yield an optical-fiber ribbon in which the adhesive deposition patterns extend to the outermost opposite optical fibers in the optical-fiber assembly. For example, in many process embodiments, the dispenser unit <NUM> repeatedly moves across the width w of the optical-fiber assembly <NUM> beyond both a first outermost optical fiber 11a in the optical-fiber assembly and an opposite second outermost optical fiber 11b in the optical-fiber assembly to apply bonding material to each optical fiber <NUM> in the optical-fiber assembly <NUM>. More generally, the dispenser <NUM> and/or the dispensing nozzle <NUM> may overshoot both edges of the optical-fiber assembly (e.g., the first outermost optical fiber 11a and the opposite second outermost optical fiber 11b in the optical-fiber assembly <NUM>) or only one edge of the optical-fiber assembly (e.g., either the first outermost optical fiber 11a or the opposite second outermost optical fiber 11b in the optical-fiber assembly <NUM>). See e.g., <FIG>.

This "overshooting" technique can be advantageous because it can produce an optical-fiber ribbon having recurring adhesive-free gaps (e.g., areas in which essentially no bonding material is present across the width w of the optical-fiber assembly for a portion of its longitudinal length) while the bonding material is applied (e.g., continuously applied) to the optical-fiber assembly. More generally, the "overshooting" technique can yield adhesive beads that bond adjacent optical fibers in regular patterns (continuous or discontinuous) across the width of the optical-fiber assembly, such as a zigzag-like pattem, a sawtooth-like pattem, or a sinusoidal-like pattern having a peak-to-valley amplitude substantially between (i) the lateral distance between the two outermost optical fibers (w - 2d) and (ii) the width w of the optical-fiber assembly. Continuous beads typically extend across the full width w of the optical-fiber assembly. (As noted, some excess bonding material may be present outside one or both outermost optical fibers in the optical-fiber ribbon.

In one process embodiment, the dispenser <NUM> and/or dispensing nozzle <NUM> continuously reciprocate an amplitude Ad across the width w of the optical-fiber assembly. This uninterrupted reciprocation can produce continuous adhesive beads (e.g., zigzag-like patterns or sinusoidal-like patterns) between the outermost optical fibers in the optical-fiber assembly, such as depicted in <FIG>. See also <FIG>.

By way of illustration, <FIG> depicts a process embodiment in which the dispensing nozzle <NUM> linearly reciprocates across the optical-fiber assembly (e.g., moves side-to-side crosswise to the longitudinal length of the optical-fiber assembly with an amplitude Ad exceeding the optical-fiber assembly's width w). This kind of "overshooting" reciprocation can yield an optical-fiber ribbon <NUM>, such as schematically depicted in <FIG>, having recurring adhesive-free gaps in which no bonding material is present across the width w of the optical-fiber assembly for a portion of its longitudinal length.

<FIG> depicts an alternative process embodiment in which the dispensing nozzle <NUM> (or other dispensing device) revolves around a central axis at a cyclical frequency r (e.g., moves in a circular or elliptical motion over the optical-fiber assembly <NUM> with an amplitude Ad exceeding the optical-fiber assembly's width w). In a related process embodiment, the dispensing nozzle <NUM> revolves around a central axis that is centrally positioned to substantially intersect the optical-fiber assembly's midline (w/<NUM>) (e.g., via a continuous or intermittent dispenser movement) to apply bonding material to each optical fiber in the optical-fiber assembly (e.g., while overshooting both edges of the optical-fiber assembly). For example, the deposited adhesive bead <NUM> across the width of the optical-fiber assembly may have a distorted sinusoidal pattern repeatedly forming (i) peaks at one edge portion of the optical-fiber assembly and (ii) valleys at an opposite edge portion of the optical-fiber assembly. Typically, these distorted sinusoidal peaks and distorted sinusoidal valleys have different respective shapes.

In related process embodiments, the dispenser <NUM> and/or the dispensing nozzle <NUM> (or other dispensing device) revolve in a plane parallel to a planar optical-fiber assembly <NUM>. This has been observed to promote faster line speeds during the manufacturing of a continuously or intermittently bonded optical-fiber ribbon <NUM>, such as an optical-fiber ribbon with a distorted sinusoidal pattern of bonding material. In this regard, an exemplary dispensing nozzle <NUM> is made of a capillary tube at the center of a metallic sleeve that is revolving in a substantially circular orbit via a servomotor (e.g., using belt-pulley system). Such a configuration reduces undesirable vibrations, which can be caused by the linear motion of a conventional reciprocating crank shaft as typically used with reciprocating nozzles, and avoids overlapping and/or uneven distribution of bonding material, which can occur using a conventional reciprocating crank shaft. Indeed, it has been observed that the use of a revolving nozzle helps to achieve linear velocities v between <NUM> and <NUM> meters per minute, which is about <NUM>-<NUM> times greater than is possible with a conventional reciprocating-crank-shaft system. For example, the linear velocity v of the optical-fiber assembly and the cyclical frequency r of the dispensing nozzle <NUM> can be controlled to achieve a pitch p (e.g., v/r) of at least about <NUM> millimeters, such as between <NUM> millimeters and <NUM> millimeters (e.g., between about <NUM> and <NUM> millimeters, such as <NUM>-<NUM> millimeters or <NUM>-<NUM> millimeters, for a <NUM>-optical-fiber ribbon). As noted, exemplary optical-fiber ribbons may have a pitch p between about 10w and 150w as normalized to the width w of the optical-fiber ribbon <NUM> (e.g., about 30w-65w, such as about 35w-50w or 40w-60w, for an exemplary sinusoidal-like deposition pattern of adhesive).

In another exemplary process embodiment, the dispenser <NUM> and/or dispensing nozzle <NUM> reciprocate an amplitude Ad in intermittent steps across the width w of the optical-fiber assembly (e.g., via linear reciprocation or revolution around a central axis). For example, the dispensing nozzle may pause when positioned above grooves in the optical-fiber assembly to deposit bonding material as longitudinal, rectilinear adhesive beads within the respective grooves (e.g., grooves between contiguous optical fibers). Such intermittent reciprocation can produce rectilinear adhesive beads (e.g., rectilinear-bead patterns) between the outermost optical fibers in the optical-fiber assembly, such as depicted in <FIG>.

By way of background and illustration, the respective cross-sectional areas of exemplary adhesive beads can be approximated by <NUM>-micron equilateral-triangle sides for <NUM>-micron optical fibers (e.g., about <NUM><NUM>) and by <NUM>-micron equilateral-triangle sides for <NUM>-micron optical fibers (e.g., about <NUM><NUM>). With a +/- <NUM> percent estimation of bead dimensions, the respective ranges for cross-sectional areas of the beads can be approximated by <NUM>-micron to <NUM>-micron equilateral-triangle sides for the <NUM>-micron optical fibers (e.g., between about <NUM><NUM> and <NUM><NUM>) and by <NUM>-micron to <NUM>-micron equilateral-triangle sides for the <NUM>-micron optical fibers (e.g., between about <NUM><NUM> and <NUM><NUM>).

In accordance with the foregoing, it is within the scope of the present disclosure to have either one substantially continuous adhesive bead or a series of discontinuous beads that secure (e.g., affix) the optical fibers within the optical-fiber ribbon. In an exemplary embodiment, the adhesive bead(s) are arranged on only one side of the optical-fiber assembly (i.e., a first side). For example, the bead(s) are arranged only on one major surface of the optical-fiber assembly, typically its upper surface (i.e., when the optical fibers are arranged in a ribbon-like manner rather than rolled up). As noted, the optical-fiber assembly can be viewed as a ribbon-like assembly defining an upper surface, a lower surface, and two side edges. The upper and lower surfaces (i.e., the respective major surfaces) are not completely flat, because they are formed of a substantially parallel arrangement of optical fibers. As such, the upper and lower surfaces have parallel longitudinal grooves between adjacent optical fibers. Those having ordinary skill in the art will understand the optical fibers may not be perfectly parallel but rather substantially parallel in practice.

As discussed, in exemplary optical-fiber ribbons according to the present invention, bonding material adhesively bonds adjacent optical fibers in an optical-fiber assembly. Two such optical-fiber ribbons may be aligned and joined using a mass-fusion splicing machine. For example, corresponding <NUM>-fiber optical-fiber ribbons may be positioned in respective <NUM>-fiber alignment chucks and, after heat stripping, cleaning, and cleaving, the two optical-fiber ribbons may be spliced at once (e.g., the corresponding optical fibers can be simultaneously butt-spliced end-to-end in the mass-fusion splicing machine).

The optical-fiber ribbon according to the present invention may be used to form optical-fiber-cable units and optical-fiber cables. An exemplary optical-fiber-cable unit has <NUM> ribbons of twelve optical fibers each. Such an optical-fiber-cable unit packs <NUM> optical fibers into a high optical-fiber density. Accordingly, in another inventive aspect, the present invention embraces an optical-fiber-cable unit including one or more optical-fiber ribbons (also according to the present invention) surrounded by a polymeric sheath. The present invention further embraces an optical-fiber cable including one or more of the optical-fiber ribbons or optical-fiber-cable units according to the present invention.

Other variations of the disclosed embodiments can be understood and effected by those of ordinary skill in the art in practicing the present invention by studying the drawings, the disclosure, and the appended claims. Unless otherwise specified, numerical ranges are intended to include the endpoints.

It is within the scope of this disclosure for one or more of the terms "substantially," "about," "approximately," and/or the like, to qualify each adjective and adverb of the foregoing disclosure, to provide a broad disclosure. As an example, it is believed those of ordinary skill in the art will readily understand that, in different implementations of the features of this disclosure, reasonably different engineering tolerances, precision, and/or accuracy may be applicable and suitable for obtaining the desired result. Accordingly, it is believed those of ordinary skill will readily understand usage herein of the terms such as "substantially," "about," "approximately," and the like.

The use of the term "and/or" includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

Claim 1:
An optical-fiber ribbon, comprising:
(i) a plurality n of respectively adjacent optical fibers extending in a longitudinal direction and arranged in parallel to form an optical-fiber assembly having a width w extending crosswise to a longitudinal length of the optical-fiber assembly; and
(ii) bonding material on the optical-fiber assembly adhesively bonding adjacent optical fibers in the optical fiber assembly, the bonding material repeatedly forming alternating first and second bonding-material patterns across the optical-fiber assembly for a portion of its longitudinal length, wherein, in the same direction along the longitudinal length of the optical fiber assembly:
the first bonding-material patterns extend across the optical-fiber assembly from a first outermost optical fiber in the optical-fiber assembly to an opposite second outermost optical fiber in the optical fiber assembly, and the second bonding-material patterns extend across the optical-fiber from the second outermost optical fiber in the optical-fiber assembly to the opposite first outermost optical fiber in the optical-fiber assembly,
the alternating first and second bonding-material patterns have respective mean lengths l1 and l2 as measured along the longitudinal length of the optical-fiber assembly, and
the alternating first and second bonding-material patterns achieve recurring adhesive free gaps in which no bonding material is present across the width w of the optical-fiber assembly for a portion of its longitudinal length, the adhesive-free gaps having a minimum length g as measured along the longitudinal length of the optical-fiber assembly,
characterised in that
g ≥ <NUM> × (l<NUM> ÷ n) if l1 ≤ l2 and g ≥ <NUM> × (l<NUM> ÷ n) if l2 ≤ l1, preferably wherein g ≥ <NUM> × (l1 ÷ n) if l1 ≤ l2 and g ≥ <NUM> × (l2 ÷ n) if l2 ≤ l1, more preferably wherein g ≥ (l1 + l2) × (n = (n-<NUM>)).