Method for fabricating a cable core including optical fibers

Abstract

There is disclosed a method for fabricating an undersea communications cable core containing optical fibers. The method includes heating a central strength member and extruding a first layer of thermoplastic elastomer onto the heated central strength member. Paying out the optical fibers from a plurality of bobbins. Helically laying the optical fibers onto the first layer of thermoplastic elastomer with a planetary motion. The optical fibers passing entirely enclosed through a separate part of a whipping prevention enclosure from the bobbins to a rotating closing die. Passing the central strength member, coated with the first layer of thermoplastic elastomer and helically wrapped with the optical fibers, through the closing die, which rotates with the rotation of the helix, applying to the optical fibers forces directed radially into the core but without applying to the optical fibers forces directed tangentially to the surface of the first layer of thermoplastic material. Extruding a second layer of thermoplastic elastomer over the fibers to merge with the first layer of thermoplastic elastomer.