Guide To The Intermittent Bonded Ribbon Production Line
An intermittent bonded ribbon production line joins fiber subunits at set intervals. Fibers remain organized for mass-fusion splicing, while the ribbon can fold into a compact cable shape. Flexible ribbon cable production is supported by this design while maintaining efficient fiber handling.
Some processes deposit bonding material before the subunit coating cures. Diffusion can occur across the shared interface before the materials cure together. Prysmian’s FlexRibbon technology provides one commercial example, and the company dates its original design to 2018. These methods illustrate how optical fiber ribbon manufacturing and fiber optic bonding operate together.
Fiber Coloring Machine Fibers In Stainless Steel Tube SZ Stranding Line
Understanding What An Intermittent Bonded Fiber Ribbon Is
An intermittent bonded fiber ribbon organizes optical fibers into small subunits. Although they remain organized for splicing, the subunits can adjust their shape to fit within a cable.
The Arrangement Of Fiber Subunits And Intermittent Bonds
Each adjacent pair or group of fibers is held together by a coating. Instead of joining along their entire length, these optical fiber subunits are connected to neighboring subunits at spaced bond points. Six two-fiber subunits may form a 12-fiber design. The configurations range from 4 to 36 fibers, and bond spacing ranges from 10 to 1,000 millimeters.
Intermittent Bonded Ribbon Production Line
Differences Between Rollable Ribbons And Conventional Flat Ribbons
In a conventional flat ribbon, the fibers remain in one fixed plane. A rollable fiber ribbon can fold between bonds while retaining fiber alignment for mass-fusion splicing. Prysmian’s FlexRibbon uses small bonding points to permit bending and folding.
Why Flexible Ribbons Support Compact, High-Density Cables
Inside a high-density fiber cable, a flexible ribbon can occupy less space. This enables cable designers to fit more fibers into a compact structure while preserving an organized fiber layout.
Intermittent Bonded Ribbon Production Line: Process And Equipment
Throughout an intermittent bonded ribbon production process, optical fibers are laid side by side along the ribbon’s length. Subunits are created when a first material coats groups containing two or more fibers. Neighboring subunits are joined at spaced points with a second material, leaving flexible sections between bonds.
Organize Adjacent Optical Fibers Into Subunits
The planned ribbon layout determines how fibers are positioned next to one another. The first coating material encloses each selected group and holds its fibers together as a subunit.
Deposit Subunit Coating And Intermittent Bonding Material
The subunits are created by fiber ribbon coating. Bonding material is applied by a discrete coating applicator between neighboring subunits at spaced intervals, not continuously along their full length.
Use Wet-On-Wet Application To Form Diffusion Zones
Wet-on-wet bonding involves depositing the bonding material before the subunit coating has cured. A diffusion zone develops as the materials intermix through their shared interface.
Cure The Subunit Coating And Bonds Together
Both the subunit coating and the intermittent bonds are cured in one curing step. Although optical fiber ribbon equipment is used for these operations, the complete equipment list, line speed, and production capacity remain unspecified.
| Production Stage | Material Or Action | Purpose |
|---|---|---|
| Optical fiber arrangement | Place fibers side by side | Set the ribbon layout |
| Formation of subunits | Coat fiber groups with the first coating material | Hold two or more fibers as subunits |
| Bonding at intervals | Deposit the second material between neighboring subunits | Connect subunits at separated bond points |
| Wet-on-wet bonding interface | Deposit bonds while the subunit coating remains uncured | Allow materials to form a diffusion zone |
| Joint curing step | Set the coating and bonds together in one step | Cure the assembled ribbon structure |
Key Production Line Stages And Process Controls
Fiber ribbon production stages take place in a specific sequence. The sequence involves arranging fibers into subunits, applying a subunit coating, placing intermittent bonds between adjacent subunits, and curing the coating and bonds together. The ribbon design must guide both optical fiber coating application and placement of the bonds.
Gaps of 5 to 100 micrometers between subunits are described in example designs. A range of 10 to 1,000 millimeters is specified for intermittent bond spacing in example designs. Bond deposits may have a diamond-like outline with narrow ends and a wider center. The disclosed examples should not be interpreted as fixed settings that apply to every line.
The selected materials, bond layout, and curing method determine ribbon manufacturing process control. Because the source material provides no line speeds, curing temperatures, or inspection intervals, do not presume any values for them.
Ribbon Flexibility, Bond Design, And Materials
Material selection and bond layout determine how the ribbon behaves during cable making and splicing. Coatings shield each fiber while permitting the subunits to flex as intended.
Choose Compatible Coating And Bonding Materials
Subunit coatings and ribbon bonding materials have distinct functions, so their formulas need not be identical. A gradual interface can be created by resins that intermix or remain at least partly soluble. Intermixing may also be encouraged by lower coating viscosity.
This interface forms a diffusion zone in which properties change gradually. Differences in color, stiffness, surface friction, tear strength, or stretch may occur within this zone. Disclosed thicknesses extend from 2 to 50 micrometers, with 5 to 15 micrometers representing a narrower range.
Control Bond Placement, Spacing, And Geometry
Where subunits remain linked or move freely is governed by bond spacing. An intermittent bond layout creates unconnected spans separating the bond points. Intersecting convex and concave curves create the saddle shape used on some bond surfaces.
Maintain Fiber Organization While Balancing Ribbon Flexibility
Unbonded spans allow the ribbon to change from a flat layout into a rolled, curled, or folded shape. A flexible fiber ribbon design bends during cable installation while keeping fibers organized for splicing.
Quality Checks To Maintain Consistent Ribbon Production
Instead of using assumed pass limits, dependable fiber ribbon quality checks assess defined features. The patent identifies design factors such as bond spacing, subunit gaps, diffusion-zone thickness, and bond shape. The patent does not, however, define inspection methods or acceptance limits.
Inspect Bond Continuity And Subunit Alignment
Check that intermittent bonds join adjacent subunits at planned locations and leave unbonded lengths between connections. Subunit alignment and gaps require checking because shifts may change ribbon shape and bond geometry.
Evaluate Ribbon Flexibility And Rollability
To evaluate ribbon rollability, watch whether it bends and gathers while keeping fibers in their original order. Throughout the ribbon design, compare bond spacing and flexibility. Treat these comparisons as design checks rather than universal production tolerances.
Verify Fiber Identification And Ribbon Configuration
Use fiber color coding to check the position of each fiber. A common 12-color sequence is blue, orange, green, brown, slate, white, red, black, yellow, violet, rose, and aqua. The color sequence may start again when a ribbon has more than 12 fibers.
Applications, Cable Integration, And Splicing Benefits
Intermittently bonded ribbons can fold inside a cable, enabling more fibers to fit into a compact design. Prysmian says FlexRibbon supports high-density ribbon cable designs, smaller diameters, and improved fiber duct utilization.
Enable High-Density Cable Designs And Better Duct Utilization
For indoor, outdoor, and indoor/outdoor applications, Prysmian offers FusionLink and MassLink with FlexRibbon. FusionLink uses dry water blocking and is available with 250 μm or 200 μm ribbon. Under NESC Heavy loading conditions, EcoSpan aerial cable can support spans of up to 300 feet. As a small-diameter outdoor option, FlexDrop can hold up to two 12-fiber ribbons.
Support Mass-Fusion Splicing And Quicker Deployment
Multiple ribbon fibers, often 12 at a time, are joined in one operation through mass-fusion splicing. On compatible ribbon routes, this method can reduce splice time. When connecting to loose-tube cable, technicians separate ribbon fibers and individually splice them with a single-fiber splicer.
Consider Indoor, Outdoor, Access, And Broadband Uses
Applications for ribbon cable include point-to-point networks, indoor FTTH systems, MTP wiring-box links, and urban trunk routes. Selecting indoor and outdoor fiber cable for each route helps match cable construction with the needs of buildings, aerial runs, and underground installations.
Conclusion
An intermittent bonded ribbon line guide brings together fiber layout, bond placement, curing, and inspection. The result is a flexible optical fiber ribbon that remains orderly during handling yet can roll or fold into compact cable designs.
The process involves applying bonds while the subunit coating is still uncured. The materials form a diffusion zone before curing together. Careful control throughout the process supports reliable fiber cable manufacturing.
Mass-fusion ribbon splicing is also enabled by flexible ribbons, helping crews splice many fibers in one operation. Prysmian describes FlexRibbon in various cable designs, including compact configurations containing up to 6,912 fibers.
Manufacturers and network planners need to manage fiber alignment, bond strength, and rollability. Achieving that balance can ease cable packaging while keeping ribbons ready for efficient installation and splicing.