Guide To The Intermittent Bonded Ribbon Production Line
At set intervals, an intermittent bonded ribbon production line joins fiber subunits. This maintains fibers in an organized arrangement for mass-fusion splicing while letting the ribbon roll or fold into a compact cable shape. Flexible ribbon cable production is supported by this design while preserving efficient fiber handling.
In some processes, bonding material is added while the subunit coating is still uncured. The materials can intermix across their interface and cure together. Prysmian’s FlexRibbon technology provides one commercial example, and the company dates its original design to 2018. Together, these methods demonstrate the relationship between optical fiber ribbon manufacturing and fiber optic bonding.
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Understanding What An Intermittent Bonded Fiber Ribbon Is
An intermittent bonded fiber ribbon groups optical fibers into small subunits. The subunits stay organized for splicing while remaining able to change shape to sit inside a cable.
The Arrangement Of Fiber Subunits And Intermittent Bonds
Each adjacent pair or group of fibers is held together by a coating. These optical fiber subunits connect to neighboring subunits at separated bond points rather than along their full length. 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
A conventional flat ribbon keeps its fibers in a single fixed plane. A rollable fiber ribbon can curl between bonds while retaining fiber alignment for mass-fusion splicing. Bending and folding are supported by the small bonding points used in Prysmian’s FlexRibbon.
How Flexible Ribbons Enable Compact, High-Density Cables
Ribbon flexibility limits the space it occupies inside a high-density fiber cable. This enables cable designers to fit more fibers into a compact structure while preserving an organized fiber layout.
Process And Equipment For An Intermittent Bonded Ribbon Production Line
The intermittent bonded ribbon production process aligns optical fibers side by side along the ribbon’s length. A first material coats groups of two or more fibers to create subunits. A second material joins neighboring subunits at spaced points and leaves flexible sections between the bonds.
Organize Adjacent Optical Fibers Into Subunits
The planned ribbon layout determines how fibers are positioned next to one another. Each selected group becomes a subunit when the first coating material encases and holds its fibers together.
Deposit Subunit Coating And Intermittent Bonding Material
Fiber ribbon coating creates the subunits. Bonding material is deposited 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
During wet-on-wet bonding, the subunit coating remains uncured when bonding material is applied. A diffusion zone develops as the materials intermix through their shared interface.
Set The Subunit Coating And Bonds In One Cure
A single curing step cures both the subunit coating and the intermittent bonds. 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 | Intended Purpose |
|---|---|---|
| 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 |
| Intermittent bonding | Apply the second material between adjacent subunits | Join subunits at spaced points |
| Wet-on-wet bonding interface | Apply bonds before the subunit coating cures | Allow materials to form a diffusion zone |
| Combined cure | 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. Optical fiber coating application and bond placement must correspond to the ribbon design.
Gaps of 5 to 100 micrometers between subunits are described in example designs. Example intermittent bond spacing extends from 10 to 1,000 millimeters. Some bond deposits take a diamond-like shape, narrowing at the ends and widening in the center. The disclosed examples should not be treated as fixed settings that apply to every line.
The selected materials, bond layout, and curing method determine ribbon manufacturing process control. The source material does not specify line speeds, curing temperatures, or inspection intervals, so these values must not be assumed.
Ribbon Flexibility, Bond Design, And Materials
Ribbon behavior during cable making and splicing depends on material choice and bond layout. Coatings protect each fiber while permitting the subunits to flex as intended.
Select Compatible Coating And Bonding Materials
Subunit coatings and ribbon bonding materials have different functions, so their formulas need not be identical. A gradual interface can be created by resins that intermix or remain at least partly soluble. Lower coating viscosity may also encourage intermixing.
This interface creates a diffusion zone in which properties change gradually. Differences in colour, stiffness, surface friction, tear strength, or stretch may occur within this zone. The disclosed thickness range is 2 to 50 micrometers, while 5 to 15 micrometers is given as a narrower range.
Control Bond Placement, Spacing, And Geometry
Bond spacing determines where fiber subunits stay connected and where they can move freely. An intermittent bond layout creates unconnected spans separating the bond points. Intersecting convex and concave curves form the saddle shape used on some bond surfaces.
Maintain Fiber Organization While Balancing Ribbon Flexibility
Unbonded spans allow the ribbon to shift from a flat layout into a rolled, curled, or folded shape. During cable installation, a flexible fiber ribbon can bend without disrupting the fiber organization needed for splicing.
Quality Checks For Consistent Ribbon Production
Instead of using assumed pass limits, dependable fiber ribbon quality checks assess defined features. Design factors named in the patent include the spacing of bonds, subunit gaps, diffusion-zone thickness, and bond shape. The patent does not, however, provide inspection methods or acceptance limits.
Inspect Bond Continuity And Subunit Alignment
Verify that intermittent bonds join adjacent subunits at the intended positions, with unbonded lengths between them. Review subunit alignment and gaps because movement can affect ribbon shape and bond geometry.
Assess 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, evaluate bond spacing and flexibility. Treat these comparisons as design checks rather than general production tolerances.
Verify Fiber Identification And Ribbon Configuration
Confirm each fiber’s position through fiber color coding. Blue, orange, green, brown, slate, white, red, black, yellow, violet, rose, and aqua make up a common 12-color sequence. For ribbons containing more than 12 fibers, this sequence may be repeated.
Cable Applications, Integration, And Splicing Benefits
By folding within a cable, intermittently bonded ribbons allow more fibers in a compact design. According to Prysmian, FlexRibbon enables high-density ribbon cable designs with smaller diameters and more effective fiber duct utilization.
Support High-Density Cable Designs And Duct Utilization
Prysmian offers FusionLink and MassLink with FlexRibbon in indoor, outdoor, and indoor/outdoor designs. FusionLink features dry water blocking and is available with 250 μm or 200 μm ribbon. EcoSpan aerial cable supports spans of up to 300 feet under NESC Heavy loading conditions. FlexDrop is a small-diameter outdoor option that accommodates up to two 12-fiber ribbons.
Support Mass-Fusion Splicing And Quicker Deployment
Multiple ribbon fibers, often 12 at a time, are spliced in one operation through mass-fusion splicing. On compatible ribbon routes, this method can reduce splice time. When connecting to loose-tube cable, technicians split ribbon fibers and individually splice them with a single-fiber splicer.
Consider Indoor, Outdoor, Access, And Broadband Uses
Ribbon cable is used in point-to-point networks, indoor FTTH systems, MTP wiring-box links, and urban trunk routes. Choosing indoor and outdoor fiber cable to suit the route aligns its construction with building, aerial, and underground requirements.
Final Conclusions
An intermittent bonded ribbon line guide covers fiber layout, bond placement, curing, and inspection. The process produces a flexible optical fiber ribbon that stays organized for handling while rolling or folding into compact cable designs.
In this process, bonds are placed before the subunit coating cures. Before they cure together, the materials form a diffusion zone. Careful control throughout the process supports reliable fiber cable manufacturing.
Flexible ribbons also support mass-fusion ribbon splicing, allowing crews to join multiple fibers at once. FlexRibbon is described by Prysmian as suitable for various cable designs, including compact configurations with up to 6,912 fibers.
For manufacturers and network planners, the priority is to coordinate fiber alignment, bond strength, and rollability. Achieving that balance can ease cable packaging while keeping ribbons ready for efficient installation and splicing.