Regroup NxM optical cable
View Patent ↗A method of manufacturing an optical cable includes providing a plurality of fibers supported by a support structure, wherein, positions of the plurality of fibers in a reference cross-section form N rows extending in a first direction and M rows extending in a second direction different from the first direction. The method includes separating fiber ends at the first cable end into N rows and connectorizing them with N connectors. The method also includes separating fiber ends at the second cable end into M rows and connectorizing them with M connectors.
1. A method of manufacturing an optical cable comprising a plurality of fibers, the method comprising:
(1) providing the plurality of fibers supported by a support structure, wherein the support structure has first and second ends,
wherein, between the first and second ends of the support structure, the plurality of fibers are straight and parallel to one another, and
wherein, in a reference cross-section between the first and second ends of the support structure, positions of the plurality of fibers form N rows extending in a first direction and M rows extending in a second direction different from the first direction;
(2) at the first end of the support structure:
separating ends of the plurality of fibers into N rows, each comprising ends of fibers extending through one of the N rows in the reference cross-section, and
connectorizing the plurality of fibers with N connectors, each connectorizing one of the N rows of fiber ends;
(3) at the second end of the support structure:
separating ends of the plurality of fibers into M rows, each comprising ends of fibers extending through one of the M rows in the reference cross section, and
connectorizing the plurality of fibers with M connectors, each connectorizing one of the M rows of fiber ends.
2. The method as defined in claim 1 , wherein the N rows of fiber ends are separated and connectorized one by one, wherein an outermost of the N rows of fiber ends is separated and connectorized before others, and then a row adjacent to the outermost row is separated and connectorized.
3. The method as defined in claim 1 , wherein step (2) comprises separating the N rows of fiber ends from one another and then attaching the N connectors to the N rows of fiber ends.
4. The method as defined in claim 1 , wherein at least a portion of the support structure is removed after at least a portion of the fibers ends are connectorized.
5. The method as defined in claim 1 , wherein the first and second directions form an angle of from 80 to 90 degrees.
6. The method as defined in claim 1 , wherein the connectors comprise a multi fiber termination (MTP) connector or a multi fiber push on (MPO) connector.
7. The method as defined in claim 1 , wherein steps (2) and (3) at last partially overlap in time.
8. The method as defined in claim 1 , wherein M and N each is greater than or equal to 4 and less than equal to 48.
9. The method as defined in claim 1 , wherein the support structure comprises a first support and a second support spaced apart from the first support.
10. The method as defined in claim 1 , wherein the support structure comprises a holder with a plurality of channels extending therethrough, wherein openings of the plurality of channels at a first end of the holder form N rows extending in one direction and M rows extending in a different direction.
11. The method as defined in claim 1 , wherein the support structure comprises N plates arranged in a stack, wherein each of the N plates supports M fibers.
12. The method as defined in claim 1 , wherein the support structure comprises a Π-shaped support.
13. The method as defined in claim 1 , wherein providing the plurality of fibers supported by the support structure comprises providing a support and adding N layers each comprising M fibers over the support, wherein each of the N layers is fixed with an adhesive.
14. An optical cable manufactured by the method defined in claim 1 .
15. An optical cable having first and second cable ends and comprising:
a support structure disposed between the first and second cable ends, and a plurality of fibers supported by the support structure,
wherein the support structure has first and second ends,
wherein the first end of the support structure is disposed between the first cable end and the second end of the support structure,
wherein, between the first and second ends of the support structure, the plurality of fibers are straight and parallel to one another;
wherein, in a reference cross-section of the plurality of fibers between the first and second ends of the support structure, positions of the plurality of fibers form N rows extending in a first direction and M rows extending in a second direction different from the first direction, and
wherein, at the first cable end, for each of the N rows extending in the first direction, a connector is attached to fibers extending through said row and, at the second cable end, for each of the M rows extending in the second direction, a connector is attached to fibers extending through said row.
16. The optical cable as defined in claim 15 , wherein the first and second directions form an angle of from 80 to 90 degrees.
17. The optical cable as defined in claim 15 , wherein the connectors comprise multi fiber termination (MTP) connectors or multi fiber push on (MPO) connectors.
18. The optical cable as defined in claim 15 , wherein M and N each is greater than or equal to 4 and less than equal to 48.
19. The optical cable as defined in claim 15 , wherein the support structure comprises a first support and a second support spaced apart from the first support.
20. The optical cable as defined in claim 15 , wherein the support structure comprises a Π-shaped support.