Fiber optic ribbon cable having enhanced ribbon stack coupling and methods thereof
A fiber optic ribbon cable includes a jacket of the cable, the jacket having a cavity defined therein, an optical element including an optical fiber and extending within the cavity of the jacket, and a dry water-blocking element extending along the optical element within the cavity. The dry water-blocking element is wrapped around the optical element with at least a portion of the dry water-blocking element disposed between another portion of the dry water-blocking element and the optical element, thereby defining an overlapping portion of the dry water-blocking element. The optical element interfaces with the overlapping portion to provide direct or indirect coupling between the optical element and the jacket.
1. A method of manufacturing a fiber optic cable, the method comprising:
arranging a plurality of optical waveguides in a ribbon stack; and
surrounding the ribbon stack with a dry insert, the dry insert comprising a layer of foam material; and
extruding a jacket around the dry insert, wherein corners of the ribbon stack interface with the dry insert to define a coupling extending longitudinally between the ribbon stack and the jacket.
2. The method of claim 1 , further comprising:
paying off at least one strength member prior to extruding the jacket such that the jacket is extruded about the at least one strength member.
3. The method of claim 1 , further comprising:
extruding a buffer tube prior to extruding the jacket such that the jacket is extruded about the buffer tube.
4. The method of claim 1 , wherein the dry insert comprises a second layer surrounding the layer of foam material.
5. The method of claim 4 , wherein the second layer is a water-swellable tape.
6. The method of claim 1 , wherein the foam material is a closed-cell foam.
7. The method of claim 6 , wherein the closed-cell foam has at least one perforation therethrough.
8. The method of claim 7 , wherein the closed-cell foam includes at least one water-swellable substance such that the closed-cell foam acts as a passive water-blocking material that inhibits water from migrating therealong and the perforation allows an activated water-swellable substance to migrate radially inward towards the plurality of optical waveguides.
9. The method of claim 1 , wherein the plurality of optical waveguides includes at least one single-mode optical fiber.
10. The method of claim 1 , wherein the ribbon stack comprises 72 optical fibers.