Patent Description:
Fiber optic communication systems are becoming prevalent in part because service providers want to deliver high bandwidth communication capabilities (e.g., data and voice) to customers. Fiber optic communication systems employ a network of fiber optic cables to transmit large volumes of data and voice signals over relatively long distances. Optical fiber splices are an important part of most fiber optic communication systems. Optical fiber splices are typically used to provide a permanent or near permanent optical connection between optical fibers. Optical splices can include single fiber splices and multi-fiber splices (e.g., mass fusion splices). In a common splicing operation, two optical fibers or two sets of optical fibers are first co-axially aligned. Often optoelectronic equipment is used to provide active alignment of the cores of the optical fibers. Once the optical fibers have been aligned, the ends of the optical fibers can be fusion spliced together usually by an electric arc. After splicing, the splice location is typically reinforced with a fiber optic fusion splice protector. A common type of fiber optic fusion splice protector is a SMOUV fiber optic fusion splice protector sold by CommScope Inc. of Hickory, North Carolina, USA. This type of fusion splice protector includes an outer shrink-fit tube, a low temperature hot melt adhesive and a stainless steel or ceramic rod which functions to add rigidity to the protector and to reinforce the splice location. <CIT> discloses related art.

The invention is defined in any independent claims. Certain examples of the disclosure are directed to a splice arrangement including first and second laminate structures positioned around a splice location at which two or more optical fibers are spliced (e.g., fusion spliced) together. The first and second laminate structures each include a polymeric sheet and an adhesive layer carried by the polymeric sheet. The adhesive layer bonds to the spliced fibers to sandwich the fibers between the polymeric sheets.

In certain implementations, the adhesive layer may include multiple layers of adhesive. For example, the adhesive layer may include a layer of soft adhesive against a layer of hard adhesive.

Certain examples of the disclosure are directed to a splice arrangement including first and second laminate structures positioned around a splice location at which two or more optical fibers are spliced (e.g., fusion spliced) together. The first and second laminate structures each include a flexible polymeric sheet and a heat activated adhesive layer carried by the flexible polymeric sheet. The sheets can be bonded together (e.g., via the adhesive).

Certain examples of the disclosure are directed to a splice arrangement including first and second films positioned across a splice location at which two or more optical fibers are spliced (e.g., fusion spliced) together. The first and second films each carry an adhesive that bonds to the optical fibers and/or to coating on the optical fibers to form a protective barrier around the splice location.

In examples, each film includes a flexible polymeric sheet. In an example, the flexible polymeric sheet includes polyester plastic.

In certain implementations, no chemicals are needed to activate the adhesive. In some examples, the adhesive is heat activated. In other examples, the adhesive is pressure activated. In still other examples, the adhesive is UV curable to activate the adhesive. In other implementations, the adhesive is chemically activated.

In some implementations, a single optical fiber is spliced to another single optical fiber at the splice location. In other implementations, a plurality of optical fibers are spliced to another plurality of optical fibers at the splice location. In some examples, the optical fibers of each plurality are loose relative to each other. In other examples, the optical fibers of each plurality are loosely ribbonized relative to each other. In still other examples, the optical fibers of each plurality are fully ribbonized relative to each other.

In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> (<NUM> inches) greater than a thickness of the spliced fibers. In certain implementations, the protective barrier may have a thickness of no more than <NUM> inches greater than a thickness of the spliced fibers.

In certain implementations, the films each have a thickness of no more than <NUM> (<NUM> inches). In certain implementations, the films each have a thickness of no more than <NUM> (<NUM> inches). In certain implementations, the films each have a thickness of no more than <NUM> (<NUM> inches). In certain implementations, the films each have a thickness of no more than <NUM> (<NUM> inches). In certain implementations, the films each have a thickness of no more than <NUM> (<NUM> inches).

In certain implementations, the protective barrier has a flexibility on par with a flexibility of the optical fibers being spliced. In certain implementations, the protective barrier is sufficiently flexible to not noticeably diminish a flexibility of the optical fibers at the splice location. In certain implementations, the protective barrier does not restrict the flexibility of the optical fibers at the splice location.

In certain implementations, the protective barrier adds rigidity or stiffness to the cable arrangement at the location of the splice. For example, the protective barrier may be no more than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may less than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may less than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may less than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement.

The protective barrier may be installed at a factory during factory splicing operations or in the field during field splicing operations. In various examples, the splice location and protective barrier may be located within a cable (e.g., within a cable jacket), within a connector (e.g., a plug connector), adjacent and external to a connector, within a module (e.g., a splice tray, a termination module, etc.), within an overmold, within a rigid body (e.g., a protective housing) containing just the protective barrier, or within an enclosure (e.g., a terminal) containing other components in addition to the protective barrier.

In certain implementations, the protective barrier can have a flexible configuration by varying the film composition and/or the film thickness. Accordingly, each protective barrier can be customized to match a particular application (e.g., protecting a splice on a rigid tray, protecting a splice within a sealed closure, protecting a splice along a flexible cable, etc.).

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.

The accompanying drawings, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure. A brief description of the drawings is as follows:.

Reference will now be made in detail to exemplary aspects of the present disclosure that are illustrated in the accompanying drawings.

Referring to <FIG>, in accordance with some aspects of the disclosure, the present disclosure is directed to a splice arrangement <NUM> including first and second fiber ribbons <NUM>, <NUM> including rows of optical fibers <NUM>, <NUM> that are fusion spliced together at a splice location <NUM>. The first and second fiber ribbons <NUM>, <NUM> each have opposite first and second major sides 202a, 202b, 204a, 204b. The splice location is positioned between first and second laminate structures <NUM>, <NUM>. The first and second laminate structures <NUM>, <NUM> each include a flexible polymeric sheet or film <NUM>, <NUM> and a heat activated adhesive layer <NUM>, <NUM> carried by the flexible polymeric sheet <NUM>, <NUM>. The adhesive layer <NUM> of the first laminate structure <NUM> is bonded to the first major sides 202a, 204a of the first and second fiber ribbons <NUM>, <NUM> and the adhesive layer <NUM> of the second laminate structure <NUM> bonded to the second major sides 202b, 204b of the first and second fiber ribbons <NUM>, <NUM>.

In certain implementations, the optical fibers <NUM>, <NUM> include bare fiber portions <NUM>, <NUM> adjacent the splice location <NUM>. The first and second laminate structures <NUM>, <NUM> are adhesively bonded to the bare fiber portions <NUM>, <NUM>.

In certain examples, the first and second fiber ribbons <NUM>, <NUM> include ribbonized portions where the optical fibers <NUM>, <NUM> are coated with a matrix material. The first and second laminate structures <NUM>, <NUM> are adhesively bonded to the ribbonized portions.

In certain implementations, the first and second laminate structures <NUM>, <NUM> do not include any reinforcing rods.

In certain implementations, the splice arrangement <NUM> does not include any reinforcing rods that extend across the splice location <NUM>.

In certain implementations, the flexible polymeric sheets <NUM>, <NUM> each have a thickness in the range of <NUM> to <NUM> (<NUM> to <NUM> inches).

In certain implementations, the flexible polymeric sheets <NUM>, <NUM> each <NUM> have a thickness less than or equal to <NUM> (<NUM> inches), or less than or equal to <NUM> (<NUM> inches), or less than or equal to <NUM> (<NUM> inches).

In certain implementations, the first and second laminate structures <NUM>, <NUM> are wider than the first and second fiber ribbons <NUM>, <NUM>. The first and second laminate structures <NUM>, <NUM> are adhesively bonded to each other at longitudinal edges 212a, 222a, 212b, 222b that are positioned along outer longitudinal edges of the first and second fiber ribbons <NUM>, <NUM>.

In certain implementations, each optical fiber <NUM>, <NUM> includes a core and a cladding layer surrounding the core.

In certain implementations, the first and second laminate structures <NUM>, <NUM> are approximately as flexible as the fiber ribbons <NUM>, <NUM>.

In certain implementations, the first and second laminate structures <NUM>, <NUM> have a first flexibility. The first and second fiber ribbons <NUM>, <NUM> have ribbonized portions with a second flexibility. The first and second flexibilities do not vary by more than <NUM> percent.

In certain implementations, the splice location <NUM> can be located within a connector body of a fiber optic connector.

In certain implementations, the heat activated adhesive <NUM>, <NUM> can be activated in an oven.

In certain implementations, the flexible polymeric sheets <NUM>, <NUM> include mylar.

In certain implementations, the splice arrangement <NUM> can be used in panels, devices, modules, cable assemblies, break-outs and cable transitions.

In certain implementations, no chemicals are needed to activate the adhesive, <NUM>, <NUM>.

In certain implementations, the splice arrangement <NUM> has a thickness less than or equal to <NUM> microns, or <NUM> microns, or <NUM> microns, or <NUM> microns, or <NUM> microns or <NUM> microns.

In accordance with other aspects of the disclosure, the splice arrangement <NUM> includes optical fibers <NUM>, <NUM> that are fusion spliced together at a splice location <NUM>; and first and second laminate structures <NUM>, <NUM> each including a flexible polymeric sheet <NUM>, <NUM> and a heat activated adhesive layer <NUM>, <NUM> carried by the flexible polymeric sheet <NUM>, <NUM>. The splice location <NUM> is positioned and bonded between the first and second laminate structures <NUM>, <NUM>.

Referring to <FIG>, in accordance with other aspects of the disclosure, the present disclosure is directed to a splice arrangement <NUM>, <NUM> including a protective barrier <NUM>, <NUM> disposed over an optical splice <NUM>, <NUM> between at least a first optical fiber <NUM>, <NUM> and a second optical fiber <NUM>, <NUM> at a splice location. The protective barrier <NUM>, <NUM> includes a first protective layer <NUM>, <NUM> and a separate, second protective layer <NUM>, <NUM> that cooperate with each other to sandwich the optical splice <NUM>, <NUM> therebetween. In certain examples, long thin strips of the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> can be referred to as "tape.

According to the claimed invention, each of the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> includes a separate film <NUM>, <NUM>, <NUM>, <NUM>, respectively. Each film <NUM>, <NUM>, <NUM>, <NUM> carries a respective adhesive layer <NUM>, <NUM>, <NUM>, <NUM>. The optical splice <NUM>, <NUM> is bonded between the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> of the first and second films <NUM>, <NUM>, <NUM>, <NUM>. In other implementations, each of the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> includes a film <NUM>, <NUM>, <NUM>, <NUM> that directly bonds to the optical fibers without an intervening adhesive layer.

Each of the optical fibers <NUM>, <NUM>, <NUM>, <NUM> has a bare fiber section <NUM>, <NUM> extending outwardly from a coated fiber section <NUM>, <NUM>. The bare fiber section <NUM>, <NUM> of each optical fiber <NUM>, <NUM>, <NUM>. <NUM> includes a core and cladding. Ends of the bare fiber sections <NUM>, <NUM> are spliced together (e.g., fused together) at the splice location. The protective barrier <NUM>, <NUM> extends over at least a portion of the bare fiber section <NUM>, <NUM> of each optical fiber <NUM>, <NUM>, <NUM>, <NUM>. In certain implementations, the protective barrier <NUM>, <NUM> also extends over a portion of the coated section <NUM>, <NUM> of each optical fiber <NUM>, <NUM>, <NUM>, <NUM>.

The films <NUM>, <NUM>, <NUM>, <NUM> traverse the splice location. The films <NUM>, <NUM>, <NUM>, <NUM> are bonded to opposite sides of the bare fibers <NUM>, <NUM> and/or opposite sides of the coated fiber sections <NUM>, <NUM> of optical fibers <NUM>, <NUM>, <NUM>, <NUM> spliced together. In some examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> carried by the films <NUM>, <NUM>, <NUM>, <NUM> bond to the optical fibers <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> bond to the bare fiber sections <NUM>, <NUM> of the fibers <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> bond to the coated fiber sections <NUM>, <NUM> of the fibers <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> bond to both the bare fiber sections <NUM>, <NUM> the coated fiber sections <NUM>, <NUM> of the fibers <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> also bond to each other at outer extents of the splice location (e.g., at edges of the film that overhang on opposite sides of the optical splice). In other examples, the films <NUM>, <NUM>, <NUM>, <NUM> bond directly to the optical fibers <NUM>, <NUM>, <NUM>, <NUM>.

In certain implementations, the protective barrier <NUM>, <NUM> does not include any reinforcing rods or aramid yarns. In certain implementations, the splice arrangement <NUM>, <NUM> does not include any reinforcing rods or aramid yarns that extend across the splice location.

In certain implementations, the splice arrangement <NUM>, <NUM> has a thickness less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns. In certain implementations, the protective barrier <NUM>, <NUM> has a thickness less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns, or less than or equal to <NUM> microns.

In certain implementations, each film <NUM>, <NUM>, <NUM>, <NUM> includes a polymeric sheet. In certain implementations, the polymeric sheets <NUM>, <NUM>, <NUM>, <NUM> each have a thickness in the range of <NUM> to <NUM> (<NUM> to <NUM> inches). In certain implementations, the polymeric sheets <NUM>, <NUM>, <NUM>, <NUM> each have a thickness less than or equal to <NUM> (<NUM> inches), or less than or equal to <NUM> (<NUM> inches), or less than or equal to <NUM> (<NUM> inches). In certain implementations, the films <NUM>, <NUM>, <NUM>, <NUM> include Mylar.

In certain implementations, the adhesive in the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> is heat activated. In some implementations, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> bond to the fibers and/or to each other upon the application of a predetermined amount of heat. In other implementations, the adhesive in the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> is pressure activated. The adhesive layers <NUM>, <NUM>, <NUM>, <NUM> bond to the fibers and/or to each other upon the application of a predetermined amount of pressure applied to the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> via the films <NUM>, <NUM>, <NUM>, <NUM>. In still other implementations, the adhesive in the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> is UV curable. The adhesive layers <NUM>, <NUM>, <NUM>, <NUM> bond to the fibers and/or to each other when exposed to a predetermined amount of UV light. In yet still other implementations, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are covered in a protective backing that can be peeled off or otherwise removed from the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> to expose the adhesive. In such implementations, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> may bond to the fibers and/or to each other upon contact without added heat, light, or pressure. In certain implementations, no chemicals are needed to activate the adhesive <NUM>, <NUM>, <NUM>, <NUM>.

In some implementations, the adhesive layer <NUM>, <NUM>, <NUM>, <NUM> varies in thickness over an axial length and/or a lateral width of the protective barrier <NUM>, <NUM>. For example, the adhesive layer <NUM>, <NUM>, <NUM>, <NUM> may be thicker around the bare fiber sections <NUM>, <NUM> of the optical fibers <NUM>, <NUM>, <NUM>, <NUM> than around the coated fiber sections <NUM>, <NUM> (see <FIG>). In other implementations, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> may have a consistent thickness over the axial length. In still other implementations, one of the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> may have a different thickness than the other adhesive layer <NUM>, <NUM>, <NUM>, <NUM>.

In some implementations, the protective barrier <NUM>, <NUM> is sufficiently flexible that the protective barrier <NUM>, <NUM> does not restrict the flexibility of the optical fibers <NUM>, <NUM>, <NUM>, <NUM> at the splice location. In certain examples, the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> are approximately as flexible as the optical fibers <NUM>, <NUM>, <NUM>, <NUM>. In other implementations, the protective barrier <NUM>, <NUM> is less flexible than the optical fibers <NUM>, <NUM>, <NUM>, <NUM>, but more flexible than a standard smouv. In an example, the protective barrier <NUM>, <NUM> has a first flexibility and the optical fibers <NUM>, <NUM>, <NUM>, <NUM> have a second flexibility that does not vary from the first flexibility by more than <NUM> percent.

In other implementations, the protective barrier <NUM>, <NUM> adds rigidity or stiffness to the cable arrangement at the splice location. For example, the protective barrier <NUM>, <NUM> may be no more than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may less than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may less than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may less than <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement. In certain examples, the protective barrier <NUM>, <NUM> may between about <NUM>% as flexible as the cable arrangement and <NUM>% as flexible as the cable arrangement.

In certain examples, the protective barrier <NUM>, <NUM> varies in flexibility over an axial length of the protective barrier <NUM>, <NUM>. In certain examples, the protective barrier <NUM>, <NUM> may be less flexible in regions where the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are thicker compared to regions where the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are thinner. For example, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> may be thicker at areas contacting the bare fiber sections <NUM>, <NUM> of the optical fibers <NUM>, <NUM>, <NUM>, <NUM> compared to areas contacting the coated fiber sections <NUM>, <NUM> of the optical fibers <NUM>, <NUM>, <NUM>, <NUM>. Accordingly, the protective barrier <NUM>, <NUM> may be more rigid at the splice location compared to the regions around the coated sections <NUM>, <NUM> of the optical fibers <NUM>, <NUM>, <NUM>, <NUM>.

In certain implementations, the first film <NUM>, <NUM> has a different flexibility or thickness than the second film <NUM>, <NUM>. In certain implementations, the first adhesive layer <NUM>, <NUM> has a different flexibility or thickness than the second adhesive layer <NUM>, <NUM>. In certain implementations, the first film <NUM>, <NUM> and the second film <NUM>, <NUM> have the same thickness and flexibility. In certain implementations, the first adhesive layer <NUM>, <NUM> and the second adhesive layer <NUM>, <NUM> have the same thickness and flexibility.

In some implementations, the optical splice <NUM> is between only the first and second optical fibers <NUM>, <NUM> (see <FIG>). In certain implementations, the films <NUM>, <NUM> are wider than the first and second optical fibers <NUM>, <NUM>. In some such implementations, the first and second protective layers <NUM>, <NUM> may adhesively bond to each other at longitudinal edges 112a, 122a, 112b, 122b on opposite sides of the first and second fibers <NUM>, <NUM> (e.g., see <FIG>). In other examples, the first and second protective layers <NUM>, <NUM> bond only to the fibers <NUM>, <NUM> (e.g., see <FIG>). In some examples, the protective layers <NUM>, <NUM> are manufactured to extend beyond the fibers by a predetermined margin. In other examples, the protective layers <NUM>, <NUM> can be trimmed to a desired size after the protective barrier is installed over the splice.

In other implementations, the optical splice <NUM> is between a first set <NUM> of optical fibers <NUM> and a second set <NUM> of optical fibers <NUM> (see <FIG>). For example, the optical splice <NUM> may be a mass fusion splice. In some examples, the optical fibers <NUM>, <NUM> of each of the first and second sets <NUM>, <NUM> are loose relative to each other (i.e., not attached to each other). In other examples, the optical fibers <NUM>, <NUM> of each set <NUM>, <NUM> are ribbonized together to form fiber ribbons <NUM>. An example ribbon <NUM> includes a ribbonized portion where the optical fibers <NUM>, <NUM> (e.g., coated sections <NUM> of the fibers) are coated or otherwise encased with a matrix material. The first and second protective layers <NUM>, <NUM> are bonded (e.g., adhesively bonded) to the ribbonized portions.

In still other examples, the optical fibers <NUM>, <NUM> of each set <NUM>, <NUM> are structured to form loose ribbons <NUM>. As the term is used herein, a "loose ribbon" <NUM> refers to a set <NUM>, <NUM> of fibers <NUM>, <NUM> that are loosely coupled together at various intervals along their length. Examples of loose ribbons <NUM> are disclosed in <CIT>, <CIT>, and <CIT>. Other examples of loose ribbons <NUM> of fibers <NUM>, <NUM> include the Rollable Ribbons™ produced by OFS Furukawa of Norcross, GA, the Spiderweb® Ribbon produced by AFL Telecommunications, LLC of Duncan, SC, and the RocketRibbon® produced by Corning Optical Communications LLC of Hickory, NC.

In certain implementations, at least the bare sections <NUM> of each set <NUM>, <NUM> of fibers <NUM>, <NUM> are arranged in a row. In certain examples, at least portions of the coated sections <NUM> of the fibers <NUM>, <NUM> also form the rows. In some implementations, the coated sections <NUM> of the fibers <NUM>, <NUM> are loose relative to each other. In other implementations, at least some portions of the coated sections <NUM> of the fibers <NUM>, <NUM> are attached to each other (e.g., at intervals along the lengths of the fibers).

Each row has a first major side and an opposite second major side that extend across the fibers <NUM>, <NUM> in the row. The first protective layer <NUM> is applied to the first major side of each row and the second protective layer <NUM> is applied to the second major side of each row. In particular, the adhesive layers <NUM>, <NUM> of the protective layers <NUM>, <NUM> extend across the optical fibers <NUM>, <NUM> in the fiber rows.

In certain implementations, the protective layers <NUM>, <NUM> are wider than the rows of the optical fibers <NUM>, <NUM>. The first and second protective layers <NUM>, <NUM> are adhesively bonded to each other at longitudinal edges 162a, 172a, 162b, 172b on opposite sides of the rows (e.g., see <FIG>). In other examples, the first and second protective layers <NUM>, <NUM> bond only to the fibers <NUM>, <NUM> (e.g., see <FIG>). In some examples, the protective layers <NUM>, <NUM> are manufactured to extend beyond the fibers by a predetermined margin. In other examples, the protective layers <NUM>, <NUM> can be trimmed to a desired size after the protective barrier is installed over the splice.

Referring to <FIG> and <FIG>, a tool <NUM> can be used to install the protective barrier <NUM>, <NUM> over an optical splice <NUM> between at least first and second optical fibers <NUM>, <NUM>, <NUM>, <NUM>. The tool <NUM> registers the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> relative to each other and relative to the optical splice <NUM>, <NUM>. The tool <NUM> also may apply the protective layers <NUM>, <NUM>, <NUM>, <NUM> over the optical splice <NUM>, <NUM> and retain the protective layers <NUM>, <NUM>, <NUM>, <NUM> in contact with the optical fibers <NUM>, <NUM>, <NUM>, <NUM> until the protective barrier <NUM>, <NUM> is formed. In certain examples, the tool <NUM> is configured to activate the adhesive of the protective layers <NUM>, <NUM>, <NUM>, <NUM>.

The tool <NUM> for installing a protective barrier <NUM>, <NUM> over an optical splice <NUM>, <NUM> includes a first part <NUM> and a second part <NUM>. The tool <NUM> is configured to receive pre-spliced optical fibers <NUM>, <NUM>, <NUM>, <NUM> (i.e., optical fibers that have already been spliced together). The tool <NUM> applies the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> around the optical splice <NUM>, <NUM>. For example, the tool <NUM> may receive the optical splice <NUM>, <NUM> with the first part <NUM> and may receive a protective layer <NUM>, <NUM> with the second part <NUM>. In certain examples, the first part <NUM> also may receive one of the protective layers <NUM>, <NUM>. In other examples, the first part <NUM> receives the first protective layer <NUM>, <NUM>, the optical splice <NUM>, <NUM> positioned over the first protective layer <NUM>, <NUM>, and the second protective layer <NUM>, <NUM> positioned over the optical splice <NUM>, <NUM> in alignment with the first protective layer <NUM>, <NUM>.

In certain examples, the tool <NUM> aligns the optical splice <NUM>, <NUM> with a central region of the protective layers <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the tool <NUM> aligns the first and second films <NUM>, <NUM>, <NUM>, <NUM> with each other at opposite sides of the optical splice <NUM>, <NUM>. In certain examples, the tool <NUM> is configured to move the protective layers <NUM>, <NUM>, <NUM>, <NUM> closer together until the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> engage the optical fibers <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the tool <NUM> is configured to move the protective layers <NUM>, <NUM>, <NUM>, <NUM> closer together until the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> engage each other. In certain examples, the tool <NUM> is configured to mechanically press the protective layers <NUM>, <NUM>, <NUM>. <NUM> together.

In certain implementations, the optical fibers <NUM>, <NUM>, <NUM>, <NUM> are received at mechanical holders <NUM> that can be mounted at the tool <NUM>. A first mechanical holder <NUM> retains the optical fiber(s) <NUM>, <NUM> at one side of the optical splice <NUM>, <NUM> and a second mechanical holder <NUM> retains the optical fiber(s) <NUM>, <NUM> at the other side of the splice <NUM>, <NUM>. In certain implementations, the mechanical holders <NUM> are removable from the tool <NUM>. In certain examples, the mechanical holders <NUM> are carried with the optical fibers <NUM>, <NUM>, <NUM>, <NUM>.

In certain implementations, the mechanical holder <NUM> clamps the optical fiber(s). In some examples, the mechanical holder <NUM> retains the bare sections <NUM>, <NUM> of the optical fiber(s) <NUM>, <NUM>, <NUM>, <NUM>. In other examples, the mechanical holder <NUM> retains the coated sections <NUM>, <NUM> of the optical fiber(s) <NUM>, <NUM>, <NUM>, <NUM>. In still other examples, the mechanical holder <NUM> retains a ribbonized section <NUM>, <NUM> of the optical fiber(s) <NUM>, <NUM>.

In certain examples, the mechanical holders <NUM> facilitate mounting the optical fibers <NUM>, <NUM>, <NUM>, <NUM> at a separate splice tool at which the optical splice <NUM>, <NUM> is formed. For example, the mechanical holders <NUM> can be installed over the respective optical fibers <NUM>, <NUM>, <NUM>, <NUM> before the fibers are spliced together. In fact, the mechanical holders <NUM> can be mounted to the fibers <NUM>, <NUM>, <NUM>, <NUM> in preparation for preparing the fibers for splicing. For example, a holder <NUM> retaining one or more fibers can be first mounted to a stripping machine (or otherwise used to mount the fiber(s) at a known location relative to the stripping machine) to hold the fiber(s) in position while a coating is removed from the fiber(s). The holder <NUM> can be moved to a splicing machine (or to a known location relative to the splicing machine) to hold the fiber(s) in position while the fiber(s) are spliced to a corresponding one or more fibers. The holder <NUM> can then be moved to the tool <NUM> for applying the protective barrier <NUM>. In examples, the holder <NUM> can be positioned at or near cleaning devices to clean the optical fiber(s) between the stripping, splicing, and/or barrier applying steps.

The first part <NUM> of the tool <NUM> defines a first holder mounting location <NUM> configured to receive the first mechanical holder <NUM>, a second holder mounting location <NUM> configured to receive the second mechanical holder <NUM>, and a first film mounting location <NUM> disposed between the first and second holder mounting locations <NUM>, <NUM>.

In certain implementations, when the holders <NUM> are disposed at the respective holder mounting locations <NUM>, <NUM>, the optical splice <NUM>, <NUM> is held at a known position on the tool <NUM>. In certain implementations, when the holders <NUM> are disposed at the respective holder mounting locations <NUM>, <NUM>, the optical splice <NUM>, <NUM> is held above the first film mounting location <NUM>.

In certain implementations, each of the holder mounting locations <NUM>, <NUM> may define pockets in which the mechanical holders <NUM> may seat. In certain examples, the mechanical holders <NUM> can be secured (e.g., latched, fasteners, snap-fit, friction-fit, etc.) at the holder mounting locations <NUM>, <NUM>. In certain examples, the optical splice <NUM>, <NUM> is tensioned when the holders <NUM> are mounted at the respective holder mounting locations <NUM>, <NUM>. In some cases, tensioning the optical splice <NUM>, <NUM> may straighten the optical fibers <NUM>, <NUM>, <NUM>, <NUM> between the mechanical holders <NUM>. In an example, the holder mounting locations <NUM>, <NUM> are spaced sufficiently far apart to tension the optical splice <NUM>, <NUM>. In another example, at least one of the holder mounting locations <NUM>, <NUM> includes a biasing member (e.g. a spring) <NUM> that biases the respective holder <NUM> away from the other holder <NUM>, thereby tensioning the optical splice <NUM>, <NUM>. For example, a biasing member <NUM> may be disposed within a pocket at the second holder mounting location <NUM> to bias any holder <NUM> mounted within the pocket away from the first holder mounting location <NUM>.

In some implementations, the second part <NUM> of the tool <NUM> defines a second film mounting location <NUM>. Each of the film mounting locations <NUM>, <NUM> is configured to hold one of the protective layers <NUM>, <NUM>, <NUM>, <NUM>. For example, the protective layers <NUM>, <NUM>, <NUM>, <NUM> may be friction-fit, vacuum-fit, clamped, latched, or otherwise held at the film mounting locations <NUM>, <NUM>. In certain examples, at least the second film mounting location <NUM> secures the protective layer <NUM>, <NUM> sufficient to move the second part <NUM> of the tool <NUM> without dislodging the second protective layer <NUM>, <NUM>. In other implementations, the second part <NUM> merely includes structure to press together protective layers <NUM>, <NUM>, <NUM>, <NUM> held by the first part <NUM> around the splice <NUM>, <NUM>.

The second part <NUM> is movable relative to the first part <NUM> between a first (e.g., open) position and a second (e.g., closed) position. In some examples, the second part <NUM> is pivotal relative to the first part <NUM>. In other examples, the second part <NUM> is slidable (i.e., movable in a straight, non-pivoting motion) relative to the first part <NUM>. In still other examples, the second part <NUM> is freely movable relative to the first part <NUM> (e.g., is a separate piece from the first part). When in the first position, the first and second parts <NUM>, <NUM> are arranged to facilitate mounting of the mechanical holders <NUM> at the holder mounting locations <NUM>, <NUM>. The protective layers <NUM>, <NUM>, <NUM>, <NUM> also can be mounted at the film mounting locations <NUM>, <NUM> when the first and second parts <NUM>, <NUM> are disposed in the first position.

The first protective layer <NUM>, <NUM> is applied to the second protective layer <NUM>, <NUM> when the first and second parts <NUM>, <NUM> of the tool <NUM> are disposed in the second position. In certain examples, the second film mounting location <NUM> opposes the first film mounting location <NUM> at least when the second part <NUM> of the tool <NUM> is disposed in the first position. The first and second film mounting locations <NUM>, <NUM> are located farther apart from each other when the second part <NUM> is disposed in the first position compared to the second position.

In certain implementations, the tool <NUM> includes an activator (shown schematically at <NUM>) configured to activate the adhesive of the protective layers <NUM>, <NUM>, <NUM>, <NUM>. In some examples, the activator <NUM> includes a heater that applies heat to the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> to melt or otherwise cause the adhesive layers to engage each other. In other examples, the activator <NUM> includes an emitter that emits UV light in a direction towards the adhesive layers <NUM>, <NUM> when the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are engaged together.

In still other examples, the activator <NUM> includes one or more pressure members that apply pressure across the protective layers <NUM>, <NUM>, <NUM>, <NUM> to press the adhesive layer <NUM>, <NUM> of the first protective layer <NUM>, <NUM> against the adhesive layer <NUM>, <NUM> of the second protective layer <NUM>, <NUM>. In certain examples, the first and second parts <NUM>, <NUM> are designed so that moving the second part <NUM> to the second position automatically applies sufficient pressure around the protective layers to activate the adhesive. In certain examples, the film mounting locations <NUM>, <NUM> are movable towards each other to apply press the protective layers <NUM>, <NUM>, <NUM>, <NUM> together.

The protective barrier <NUM>, <NUM> is sized and configured to allow the splice arrangement <NUM>, <NUM> to be utilized in various applications. In an example, the protective barrier <NUM>, <NUM> is sized and configured to enable the splice arrangement <NUM>, <NUM> to be located within a connector body of a fiber optic connector. In an example, the protective barrier <NUM>, <NUM> is sized and configured to enable the splice arrangement <NUM>, <NUM> to be located just outside of a fiber optic connector. In an example, the protective barrier <NUM>, <NUM> is sized and configured to enable the splice arrangement <NUM>, <NUM> to be located within a splice tray. In an example, the protective barrier <NUM>, <NUM> is sized and configured to enable the splice arrangement <NUM> to be located within a cable (e.g., within a buffer tube and/or strength layer and/or cable jacket). In an example, the protective barrier <NUM>, <NUM> is sized and configured to enable the splice arrangement <NUM>, <NUM> to be located within a sealed reinforcing element (e.g., an overmolded shroud, or other protective casing). In an example, the protective barrier <NUM>, <NUM> is sized and configured to enable the splice arrangement <NUM>, <NUM> to be located within a larger enclosure (e.g., a multi-service terminal or other enclosure holding components other than the optical splice arrangement). In certain implementations, the splice arrangement <NUM>, <NUM> can be used in panels, devices, modules, cable assemblies, break-outs and cable transitions.

In certain implementations, the configuration of the protective barrier is flexible. Accordingly, a protective barrier can be customized for a particular application by varying the film composition and/or the film thickness. For example, a protective barrier having a first degree of flexibility may be used within a rigid closure and a protective barrier having a second, different degree of flexibility may be used along a cable (i.e., under the cable jacket).

In use, a protective barrier is installed about an optical splice by positioning the optical splice between a first adhesive layer carried by a first film and a second adhesive layer carried by a second film; moving the first and second films towards each other until the adhesive layers engage around the optical splice; and activating the adhesive layers of the first and second films.

In some examples, the optical splice is a splice between a first single optical fiber and a second single optical fiber. In other examples, the optical splice is a splice between a first plurality of optical fibers and a second plurality of optical fibers. For example, the optical splice may be a mass fusion splice.

In certain implementations, the spliced optical fibers are positioned on a tool that applies the protective barrier. In certain examples, the spliced optical fibers are positioned on the tool using mechanical holders (e.g., fiber clamps). In examples, the optical fibers are positioned on the tool so as to put tension on the optical splice. For example, one or both mechanical holders may be spring-biased away from the other mechanical holder.

In some implementations, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are activated before moving the first and second films <NUM>, <NUM>, <NUM>, <NUM> towards each other. For example, a protective backing may be removed from the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> before moving the films <NUM>, <NUM>, <NUM>, <NUM> towards each other.

In other implementations, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are activated after the first and second films <NUM>, <NUM>, <NUM>, <NUM> have been moved towards each other. For example, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> may be activated when the adhesive layers are in contact with each other. In some examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are activated by applying heat. In other examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are activated by applying pressure. In other examples, the adhesive layers <NUM>, <NUM>, <NUM>, <NUM> are activated by applying UV light.

In certain implementations, the first and second films <NUM>, <NUM>, <NUM>, <NUM> are moved towards each other by moving the first and second parts <NUM>, <NUM> of the tool <NUM> towards each other. In an example, one or both of the first and second parts <NUM>, <NUM> may be pivoted towards the other. In another example, one or both of the first and second parts <NUM>, <NUM> may be slid towards the other. In another example, the first and second parts <NUM>, <NUM> are separable from each other and, therefore, freely movable relative to each other.

In certain implementations, the protective layers <NUM>, <NUM>, <NUM>, <NUM> are configured to indicate a proper orientation to the technician applying the protective layers <NUM>, <NUM>, <NUM>, <NUM> to form the protective barrier <NUM>, <NUM> about the splice <NUM>, <NUM>. In certain examples, the protective layers <NUM>, <NUM>, <NUM>, <NUM> are configured to facilitate distinguishing the adhesive side of the protective layer <NUM>, <NUM>, <NUM>, <NUM> from the non-adhesive side. In certain examples, the adhesive side and non-adhesive side have different colors. In certain examples, the adhesive side and non-adhesive side have different textures (e.g., glossy versus matte, smooth versus textured, etc.). In still other implementations, each protective layer <NUM>, <NUM>, <NUM>, <NUM> may be cut (e.g., notched at a pre-determined corner) to distinguish the adhesive side from the non-adhesive side.

According to the claimed invention, indicia (e.g., inked indicia) are carried by the protective layers <NUM>, <NUM>, <NUM>, <NUM> to distinguish the adhesive and non-adhesive sides. In certain examples, the indicia is deposited or otherwise disposed between the film <NUM>, <NUM>, <NUM>, <NUM> and the adhesive layer <NUM>, <NUM>, <NUM>, <NUM> of each protective layer <NUM>, <NUM>, <NUM>, <NUM>. The indicia include text. In other examples not part of the claimed invention, the indicia includes pictures or one or more blocks of color.

<FIG> illustrate a protective layer <NUM>, <NUM>, <NUM>, <NUM> including example indicia <NUM>. According to the claimed invention, the indicia <NUM> includes text. In an example, the text <NUM> extends over a majority of the protective layer <NUM>, <NUM>, <NUM>, <NUM>. In an example, the protective layer <NUM>, <NUM>, <NUM>, <NUM> is elongate along a length and the text spans a majority of the length. In other examples, the text <NUM> may span less than half of the length protective layer <NUM>, <NUM>, <NUM>, <NUM>. In an example, a height of the letters of the text span a majority of a width of the protective layer <NUM>, <NUM>, <NUM>, <NUM>. In other examples, the text <NUM> may span less than half of the width of the protective layer <NUM>, <NUM>, <NUM>, <NUM>. In certain examples, the text is correctly oriented when the protective layer <NUM>, <NUM>, <NUM>, <NUM> is arranged adhesive side down.

A technician applying a protective barrier <NUM>, <NUM> about a splice <NUM>, <NUM> would position (e.g., using the tool <NUM>) a first one of the protective layers <NUM>, <NUM>, <NUM>, <NUM> so that the text <NUM> was either upside-down or reversed (i.e., reading right-to-left) below the splice <NUM>, <NUM>. The technician would then position a second one of the protective layers <NUM>, <NUM>, <NUM>, <NUM> so that the text <NUM> was right-side up and reading left-to-right above the splice <NUM>, <NUM>. The technician would then bring the first and second protective layers <NUM>, <NUM>, <NUM>, <NUM> together (e.g., using the tool <NUM>) to sandwich the splice <NUM>, <NUM> therebetween. In some examples, the technician would then apply heat to active the adhesive sides of the protective layers to secure the protective layers about the splice <NUM>, <NUM>. In other examples, the technician would remove blank films to uncover the adhesive side prior to bringing the adhesive sides (e.g., pressure-activated adhesive sides) together.

In certain implementations, each protective layer <NUM>, <NUM>, <NUM>, <NUM> can include multiple types of indicia to facilitate properly orienting the protective layer. In certain examples, an opaque coloring (e.g., white, black, gray, red, blue, green, etc.) <NUM> can form a background for the text <NUM>. In certain examples, the opaque coloring <NUM> may extend over only a portion of the protective layer <NUM>, <NUM>, <NUM>, <NUM>. A remainder of the background may be transparent, allowing the technician to see through the protective layer <NUM>, <NUM>, <NUM>, <NUM>. In an example, the opaque coloring <NUM> overlaps a portion of the text <NUM>.

Claim 1:
A splice arrangement (<NUM>) comprising:
optical fibers (<NUM>, <NUM>) that are fusion spliced together at a splice location (<NUM>); and
a protective barrier (<NUM>, <NUM>) disposed across the splice location, the protective barrier (<NUM>, <NUM>) including first and second films (<NUM>, <NUM>, <NUM>, <NUM>), each of the first and second films carrying a respective adhesive layer (<NUM>, <NUM>, <NUM>, <NUM>), the splice location being bonded between the adhesive layers of the first and second films, characterized in that the first and second films include text indicia (<NUM>) properly readable when viewed from non-adhesive sides of the first and second films, wherein the first and second films are aligned, so that the first and second adhesive layers (<NUM>,<NUM>,<NUM>,<NUM>) face each other, with the text indicia facing in different directions.