Hughes Aircraft Company

Other

Gregory LoStracco

Hui-Pin Hsu

George W LeCompte

Daniel K Schotter

Ronald B Chesler

Gary R Redford

George H Hulderman

John F Christian

An optical fiber pack (42) having layers (52) of optical fiber (22) is formed on a bobbin (32) using an ultravlolet-curable adhesive. A layer (50) of a UV-curable adhesive is deposited, and a length of the optical fiber (52) is wound over the layer (50) of ultraviolet-curable adhesive. Ultraviolet radiation is directed at the layer (50) of ultraviolet-curable adhesive through the layer (52) of optical fiber wound over the layer (50) of adhesive, to cure the adhesive. The approach can be used, for example, to apply adhesive to entire layers of the optical fiber, or to tack the ends of the optical fiber layers into place.

Use of ultraviolet-curable adhesive in preparation of optical fiber

An optical fiber dispenser (40) includes a bobbin (42), an optical fiber pack (52) overlying the bobbin (42), and a thermal expansion accommodation layer (50) positioned between the bobbin (42) and the optical fiber pack (52 ). The thermal expansion accommodation layer (50) is made of a material, such as a silicone elastomer, that is readily deformable to accommodate the different longitudinal coefficients of thermal expansion of the bobbin (42) and the optical fiber pack (52). The thermal expansion accommodation layer (50) has a thickness, typically more than about 1/8 inch for a conventional bobbin size, sufficient to reduce any thermal stresses produced by the different longitudinal coefficients of thermal expansion to less than the failure strength of the optical fiber pack (52).

Optical fiber dispenser with thermal expansion accommodation layer

A method for preparing an optical fiber canister includes providing a length of a wire (44) having a diameter of about that of the optical fiber (60), and winding the wire (44) onto a mandrel (40) in a preselected winding pattern to form a base layer (46). A replicating strip (48) having a flexible substrate (50) with a patterning layer (52) of b-staged epoxy on one side thereof is provided, and the patterning layer (52) is pressed against the base layer (46) to form a groove pattern (62) in the patterning layer (52). The b-staged epoxy layer (52) is cured to harden it to preserve the groove pattern, and then the flexible substrate (50) is applied to an optical fiber bobbin (56) with the grooved patterning layer (52) facing outwardly. An optical fiber (60) is wound into the groove (62) of the patterning layer (52) to form an optical fiber pack (66).

Preparation of an optical fiber canister

A composite bobbin (10) for use in an optical fiber canister has a surface with a spirally groove base layer (38) in which the first layer of an optical cable (42) is wound. The base layer (38) is prepared by coating the external surface of a central portion (12) of the bobbin (10) with an adhesive layer (16) of a curable two-stage epoxy, winding a tensioned wire (22) in a spiral pattern along the length of the central portion (12), and heating the bobbin (10) to cure the epoxy. The proper combination of tension and curing cycle permits the grooves of the base layer (38) to be formed to a depth of about 1/3 of the diameter of the optical cable (42).

Optical cable composite-material bobbin with grooved base layer

A winding form baselayer (20) has a flexible insulative substrate (22) on which a plurality of parallel spaced apart filament cable guides (24) are located. Optionally, the guides (24) can be formed by depositing a metal layer and etching out spaces (W) between the guides or plating the individual guides. A wound pack (28) is produced by winding a first filament layer (26) into the spaces (W) with subsequent layers wound over the first layer in conventional manner. In an alternate version, the filament cable guides (52) are etched into the top side of a metal sheet and the opposite side is etched into a diagonally arranged set of struts (56) which provide lateral resiliency for the entire baselayer (46).

Base layer for an optical fiber wound pack

A fiber optic cannister includes a compliant baselayer underlying layers of an optical fiber wound onto a bobbin. The compliant material is useful to form a base layer over which the layers of optical fiber are wound. The use of such a compliant baselayer eliminates the need to fabricate and stock expensive baselayer wire material.

Fiber optic canister with compliant baselayer

A fiber dispenser 10 which provides a bobbin 12 with an expansion ring 30 mounted on an end thereof. The expansion ring 30 is coaxial with the bobbin 12 and permits the use of a nontapered bobbin for high speed dispensation applications. In a specific embodiment, the invention includes a mechanism for adjusting the diameter of the expansion ring as the fiber is dispensed. A further, more specific embodiment includes a mechanism 42, 44 for adjusting the longitudinal position of the expansion ring 30 as the fiber 21 is wound thereon.

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Tucson, AZ, United States of America

Gregory LoStracco