CHAPTER- 5

CONSTRUCTIONAL FEATURES OF OPTICAL FIBRE CABLE

In this chapter Main component parts of an optical fibre cable. Loose tube, slotted core and Ribbon type structure of O.F. cables.

5. 1. The main component parts of an optical fibre cable are as under. 1. 2. 3. core Cladding Buffers (a) Primary coating (b) secondary coating i. ii. iii. 4. Strength member 5. Fillers 6. core wrap 7. cable sheath 8. Armour 9. Jacketing 5.2 1. The individual components are explained here under: CORE Loose buffer Tight buffer open channel

As discussed earlier core is a central tube of very thin size approximately 8um made up of glass and carries light signals from transmitter to receiver 2. CLADDING

This surrounds core cylindrically and is having lesser refractive index as compared to the core. Due to total internal reflection phenomenon it confines the light signal to the core. 3. (a) BUFFERS Primary coating

Acrylate, Silicon rubber or lecquer is applied as coating immediately after being drawn (manufacturing process). It works as mechanical protection during the subsequent stages of manufacturing. Typical diameter after this coating is 250-300um (b) Secondary coating

An additional buffer (secondary coating) is also added during manufacturing process. These are of three types.(Ref fig. 5.1)

Fig 5.1 Structure Of O.F. Cable i) Loose buffer

More than one fibre can be inserted in a single plastic tube. The dia of the tube is several times more than that of fibre dia (after primary coating). This arrangement protects fibre from mechanical forces. It also eliminates microbending of fibre Its loose tube is usually filled with jelly for protection from moisture. Typical dia after this loose tube is 1.5 to 2mm ii) Tight buffer

In this case plastic coating is directly applied over the primary coating. This arrangement provides better crush and impact resistance but it may produce micro bends due to stresses. Such types are also affected due to temperature variations, plastic expansion, contraction which is different from glass. These are mainly used as indoor cables. iii) Open channel

In this type of cables, fibres are located in groove formed in the central strength member. Like loose tube fibres in this type also fibres are free to move within the cable avoiding tensile stress. Fibres are protected from moisture by filling the cable with jelly or similar compound. 4. STRENGTH MEMBER

Optical fibres are stranded helically around the strength member. Function of each strength member is to hold the cable with low strain and to provide mechanical strength. Strength member provided is normally of the following types; a) Steel wires b) Plastic material. c) Textile fibres d) Fibre glass epoxy rods

5.

Fillers

Fillers are employed to maintain spacing of coated fibres and insulated conductors if any, to provide cushioning to the fibres and to give shape to the cable. Typical materials are PVC, Polythylene, low density cellulose paper, spun bonded polyster. The cable core is generally filled with a blocking or filling compound to prevent moisture entry. 6. CORE WRAP

This is in the form of a tape and it holds the assembly of fibre, filler and provides heat barrier to fibre during extrusion process of outer sheath. Materials used are polyster cellulose paper etc. 7. CABLE SHEATH

This protects cable from environmental damage. It makes moisture, chemical and fire resistant. Sheath material can be high density polyethylene. PVC sheaths are common in fibres installed for indoor applications 8. ARMOUR

Whenever cables are to be buried directly in the earth to protect the cable against rodent attacks, armouring is considered essential. Armouring can be by steel wire or steel tapes. Armouring gives extra strength and improves flexibility for easy handling. In case of RE area the problem of high voltage induced can be reduced by isolating the armour at periodical interval(say) every 1.5 Km. The small or normal gap can be protected by applying epoxy resin etc. For details of I.R. Specification refer Chapter 9. 9. JACKETING

Normally outer most sheath which is called jacketing provides protection from chemicals acids alkalis, solvents etc. Material used for this purpose are polyethylene, polyurethane, PVC, nylon etc. 5.3. Specification of optic fibre cable parameters used in CCG-VIRAR section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Construction No. of fibres Type of fibre Core thickness Acrylate Coat dia Wave length Attenuation Dispersion Cable weight Minimum bending diameter Dia of the cable Life under tropical conditions : : : : : : : : : : : 500 mm : Min 20 years. 20.3 mm. Loose tube 10 monomode 2.5 micron 250 micron 1300 + 25nm. 0. 5 db/Km 6ps/km-nm. 600 Kg/Km

13. Armoured cable rodent attack. 5.4. CABLE CONFIGURATION

Protection against

There are three most popular structures which are in use a) Loose tube structure b) Slotted core Structure. c) Ribbon Structure a) Loose tube Structure (Ref fig 5.4.a)

This type of structure uses protective loose tube made of thermo plastic material. The tube may contain one or more fibres. These tubes are then stranded helically in continuous or alternate paths around a central strength member. The central strength member used in the cables are steel or fibre reinforced plastic (for non metallic cables). These tubes are generally filled with selected materials which have stable physical characteristics over a wide temperature range. The cable interstices are filled with moisture resistant filling compound to retard the ingress and axial migration of water. The cable core is wrapped with a wrapping tape. b) Slotted core Structure (Ref. fig. 5.4b)

This type of cable consists of a plastic rod extruded over a central strength member assuring good mechanical and thermal performance of the structure. V. grooves or slots are cut in the surface of the plastic rod. These groves or slots may contain one or more fibres protected only by primary coating. After the fibres have been inserted the slotted core is closed by applying plastic or synthetic covering and wherever necessary Slots are filled with a filling compound having stable physical characteristics over a wide range of temperature. Each slotted core may either be used alone with a protective outer jacket or assembled with similar cable units before providing outer protection. c) Ribbon structure (Ref. fig. 5.4C)

This type of structure is adopted when the requirement of channel is very high. The ribbons of fibres (containing 12 fibres or less) are stacked in slotted core structure. These slotted core units may then be stranded around the central strength member.

Fig.5.4(b)(i):SLOTTED CORE DESIGN

Fig.5.4(b)(ii):10 FIBRE CABLE UNIT (SLOTTED CORE STRUCTURE)

Fig. 5.4(b)(iii) CONSTRUCTION OF A 600 FIBRE CABLE 1. What are the main component parts of an optical fibre cable? 2. What are the materials used for primary coating and secondary coating ? 3. How the primary coating is removed while doing splicing ?