Optical cables with lubricated optical fibers and methods of formation thereof
Embodiments of the present disclosure provide an apparatus and method for manufacturing of optical cable buffer tubes using an emulsion lubricant. In an embodiment, an optical cable includes a plurality of buffer tubes. Each buffer tube includes a bundle of optical fibers comprising an outer surface area, a swellable-thread comprising a hydrophilic base material comprising water, and a layer of silicone contacting at least a part of the outer surface area.
1. An optical cable comprising:
a plurality of buffer tubes, each buffer tube comprising:
a bundle of optical fibers comprising an outer surface area,
a swellable-thread comprising a hydrophilic base material comprising water, and
a layer of silicone comprising water, the layer of silicone contacting at least a part of the outer surface area.
2. The optical cable of claim 1 , wherein the swellable-thread is disposed around one or more of the bundle of optical fibers.
3. The optical cable of claim 1 , wherein the swellable-thread is interwoven with one or more of the bundle of optical fibers.
4. The optical cable of claim 1 , wherein the bundle of optical fibers is disposed around the swellable-thread.
5. The optical cable of claim 1 , further comprising:
an outer jacket surrounding the plurality of buffer tubes; and
a central strength member, the plurality of buffer tubes disposed around the central strength member.
6. The optical cable of claim 1 , wherein the swellable-thread is a tape, a yarn carrying a water-swellable material, or an ultraviolet cured swellable coating.
7. The optical cable of claim 1 , wherein a coating, inking, and emulsion system of the bundle of optical fibers is capable of withstanding a period of at least 90 days of water exposure or humidity conditioning testing at 60 degrees Celsius (° C.) with an increase in attenuation that is less than 0.05 decibel/kilometer (dB/km) at a wavelength of 1550 nanometer (nm).
8. The optical cable of claim 1 , wherein a coating, inking, and emulsion system of the bundle of optical fibers is capable of withstanding a period of at least 90 days of water exposure or humidity conditioning testing at 60 degrees Celsius (0 C) with an increase in attenuation that is less than 0.1 decibel/kilometer (dB/km) at a wavelength of 1550 nanometer (nm).
9. A buffer tube comprising:
a bundle of optical fibers comprising an outer surface area,
a swellable-thread comprising a hydrophilic base material comprising water, and
a layer of silicone applied as an emulsion lubricant to the bundle of optical fibers, the layer of silicone contacting at least a part of the outer surface area, the emulsion lubricant comprising silicone, the water, and an emulsifying agent.
10. The buffer tube of claim 9 , wherein the swellable-thread comprises water absorbed from the emulsion lubricant to provide the layer of silicone on the outer surface area of the bundle of optical fibers.
11. The buffer tube of claim 9 , wherein the layer of silicone comprises a silicone region having a thickness between about 0.5 nanometers (nm) and 5 nm.
12. The buffer tube of claim 9 , wherein the swellable-thread is disposed around one or more of the bundle of optical fibers.
13. The buffer tube of claim 9 , wherein the swellable-thread is interwoven with one or more of the bundle of optical fibers.
14. The buffer tube of claim 9 , wherein the bundle of optical fibers is disposed around the swellable-thread.
15. The buffer tube of claim 9 , wherein the swellable-thread is a tape, a yarn carrying a water-swellable material, or an ultraviolet cured swellable coating.
16. The buffer tube of claim 9 , wherein the layer of silicone provides mechanical coupling, reduces stiction, and static charge buildup during cable access, cable repair, and splicing.
17. An optical cable comprising:
a central strength member disposed in a central region of the optical cable; and
a buffer tube disposed in a peripheral region of the optical cable, the buffer tube comprising
a swellable-thread comprising a hydrophilic base material comprising water,
a bundle of optical fibers disposed around the swellable-thread, the bundle of optical fibers comprising an outer surface area, and
a layer of silicone applied as an emulsion lubricant to the bundle of optical fibers, the layer of silicone disposed at an inner surface contacting at least a part of the outer surface area of the bundle of optical fibers, the emulsion lubricant comprising silicone, the water, and an emulsifying agent.
18. The optical cable of claim 17 , further comprising:
an outer jacket disposed in the peripheral region and surrounding the buffer tube.
19. The optical cable of claim 17 , wherein the layer of silicone comprises a silicone region having a thickness between about 0.5 nanometers (nm) and 5 nm.
20. The optical cable of claim 17 , wherein the layer of silicone provides mechanical coupling, reduces stiction, and static charge buildup during cable access, cable repair, and splicing.
21. The optical cable of claim 17 , wherein the layer of silicone increases lubricity of the bundle of optical fibers.
22. The optical cable of claim 17 , wherein a coating, inking, and emulsion system of the bundle of optical fibers is capable of withstanding a period of at least 90 days of water exposure or humidity conditioning testing at 60 degrees Celsius (0 C) with an increase in attenuation that is less than 0.05 decibel/kilometer (dB/km) at a wavelength of 1550 nanometer (nm).
23. The optical cable of claim 17 , wherein a coating, inking, and emulsion system of the bundle of optical fibers is capable of withstanding a period of at least 90 days of water exposure or humidity conditioning testing at 60 degrees Celsius (0 C) with an increase in attenuation that is less than 0.1 decibel/kilometer (dB/km) at a wavelength of 1550 nanometer (nm).
24. The optical cable of claim 17 , wherein the swellable-thread comprises water absorbed from the emulsion lubricant to provide the layer of silicone on the outer surface area of the bundle of optical fibers.