Fiber Cable Construction

Fiber optic cables contain one or more optical fibers. The optical fiber elements are typically individually coated with plastic layers and contained in a protective tube suitable for the environment where the cable will be deployed.

In practical fibers, the cladding is usually coated with a tough resin buffer layer, which may be further surrounded by a jacket layer, usually plastic. These layers add strength to the fiber but do not contribute to its optical wave guide properties. Rigid fiber assemblies sometimes put light-absorbing (“dark”) glass between the fibers, to prevent light that leaks out of one fiber from entering another. This reduces cross-talk between the fibers, or reduces flare in fiber bundle imaging applications.

For indoor applications, the jacketed fiber is generally enclosed, with a bundle of flexible fibrous polymer strength members like Aramid or Kevlar, in a lightweight plastic cover to form a simple cable. Each end of the cable may be terminated with a specialized optical fiber connector to allow it to be easily connected and disconnected from transmitting and receiving equipment.

An optical fiber breakout

For use in more strenuous environments, a much more robust cable construction is required. In loose-tube construction the fiber is laid helically into semi-rigid tubes, allowing the cable to stretch without stretching the fiber itself. This protects the fiber from tension during laying and due to temperature changes. Loose-tube fiber may be “dry block” or gel-filled. Dry block offers less protection to the fibers than gel-filled, but costs considerably less. Instead of a loose tube, the fiber may be embedded in a heavy polymer jacket, commonly called “tight buffer” construction. Tight buffer cables are offered for a variety of applications, but the two most common are “Breakout” and “Distribution”. Breakout cables normally contain a rip cord, two non-conductive dielectric strengthening members (normally a glass rod epoxy), an aramid yarn, and 3 mm buffer tubing with an additional layer of Kevlar surrounding each fiber. Distribution cables have an overall Kevlar wrapping, a ripcord, and a 900 micrometer buffer coating surrounding each fiber. These fiber units are commonly bundled with additional steel strength members, again with a helical twist to allow for stretching.

Modern fiber cables can contain up to a thousand fibers in a single cable, so the performance of optical networks easily accommodates even today’s demands for bandwidth on a point-to-point basis. However, unused point-to-point potential bandwidth does not translate to operating profits, and it is estimated that no more than 1% of the optical fiber buried in recent years is actually ‘lit’. While unused fiber may not be carrying traffic, it still has value as dark backbone fiber. Companies can lease or sell the unused fiber to other providers who are looking for service in or through an area. Many companies are “overbuilding” their networks for the specific purpose of having a large network of dark fiber for sale. This is a great idea as many cities are difficult to deal with when applying for permits and trenching in new ducts is very costly.

Modern cables come in a wide variety of sheathings and armor, designed for applications such as direct burial in trenches, dual use as power lines, installation in conduit, lashing to aerial telephone poles, submarine installation, or insertion in paved streets. In recent years the cost of small fiber-count pole-mounted cables has greatly decreased due to the high Japanese and South Korean demand.

The benefits of Fiber Optic cables quite simply are the following:

• SPEED
• BANDWIDTH
• DISTANCE
• RESISTANCE
• MAINTENANCE

Fiber optic cables are steadily replacing copper wire as an appropriate means of communication signal transmission. They span the long distances between local phone systems as well as providing the backbone for many network systems.

Other system users include cable television services, university campuses, office buildings, industrial plants, and electric utility companies.

A fiber-optic system is similar to the copper wire system that fiber-optics is replacing. The difference is that fiber-optics use light pulses to transmit information down fiber lines instead of using electronic pulses to transmit information down copper lines. Looking at the components in a fiber-optic chain will give a better understanding of how the system works in conjunction with wire based systems.

At one end of the system is a transmitter. This is the place of origin for information coming on to fiber-optic lines. The transmitter accepts coded electronic pulse information coming from copper wire. It then processes and translates that information into equivalently coded light pulses. A light-emitting diode (LED) or an injection-laser diode (ILD) can be used for generating the light pulses. Using a lens, the light pulses are funneled into the fiber-optic medium where they travel down the cable. The light (near infrared) is most often 850nm for shorter distances and 1,300nm for longer distances on Multi-mode fiber and 1300nm for single-mode fiber and 1,500nm is used for for longer distances.

Think of a fiber cable in terms of very long cardboard roll (from the inside roll of paper towel) that is coated with a mirror on the inside.
If you shine a flashlight in one end you can see light come out at the far end – even if it’s been bent around a corner.

Light pulses move easily down the fiber-optic line because of a principle known as total internal reflection. “This principle of total internal reflection states that when the angle of incidence exceeds a critical value, light cannot get out of the glass; instead, the light bounces back in. When this principle is applied to the construction of the fiber-optic strand, it is possible to transmit information down fiber lines in the form of light pulses. The core must a very clear and pure material for the light or in most cases near infrared light (850nm, 1300nm and 1500nm). The core can be Plastic but most are made from glass. Glass optical fibers are almost always made from pure silica, but some other materials, such as fluorozirconate, fluoroaluminate, and chalcogenide glasses, are used for longer-wavelength infrared applications

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