Guide To The Intermittent Bonded Ribbon Production Line
At defined intervals, an intermittent bonded ribbon production line joins fiber subunits. Fibers remain organized for mass-fusion splicing, while the ribbon can roll into a compact cable shape. Flexible ribbon cable production is supported by this design while maintaining efficient fiber handling.
Some processes apply bonding material before the subunit coating cures. The materials can diffuse across their interface and 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 work in combination.
Fiber Secondary Coating Line Fiber Draw Tower Fiber Secondary Coating Line
Understanding What An Intermittent Bonded Fiber Ribbon Is
An intermittent bonded fiber ribbon organizes optical fibers into small subunits. The subunits stay organized for splicing while remaining able to change shape to fit inside a cable.
The Arrangement Of Fiber Subunits And Intermittent Bonds
Each neighboring 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. Configurations can contain 4 to 36 fibers, with bonds spaced from 10 to 1,000 millimeters apart.
Intermittent Bonded Ribbon Production Line
How Rollable Ribbons Differ From Conventional Flat Ribbons
A conventional flat ribbon holds its fibers in a single fixed plane. Between bonds, a rollable fiber ribbon can fold without losing the fiber alignment needed for mass-fusion splicing. Bending and folding are supported by the discrete bonding points used in Prysmian’s FlexRibbon.
How Flexible Ribbons Enable Compact, High-Density Cables
Ribbon flexibility reduces the space it occupies inside a high-density fiber cable. Cable designers can therefore accommodate more fibers in a compact structure without sacrificing an organized fiber layout.
Intermittent Bonded Ribbon Production Line: Process And Equipment
Throughout an intermittent bonded ribbon production process, optical fibers are arranged side by side along the ribbon’s length. A first material coats groups of two or more fibers to form subunits. Neighboring subunits are joined at separate points with a second material, leaving flexible sections between bonds.
Arrange Adjacent Optical Fibers Into Subunits
Fibers are placed beside one another according to the planned ribbon layout. The first coating material encloses each selected group and holds its fibers together as a subunit.
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.
Create Diffusion Zones Through Wet-On-Wet Application
Wet-on-wet bonding involves depositing the bonding material before the subunit coating has cured. The materials diffuse across their shared interface to form a diffusion zone.
Set The Subunit Coating And Bonds In One Cure
A single curing step sets both the subunit coating and the intermittent bonds. Optical fiber ribbon equipment performs these operations, although a complete equipment list, line speed, and production capacity are not specified.
| Process Stage | Material Or Operation | Intended Purpose |
|---|---|---|
| Fiber arrangement | Arrange fibers next to one another | 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 | Connect subunits at separated bond points |
| Wet-on-wet interface | Apply bonds before the subunit coating cures | Enable formation of a diffusion zone between the materials |
| Joint curing step | Set the coating and bonds together in one step | Cure the assembled ribbon structure |
Main Production Line Stages And Process Controls
Fiber ribbon production stages take place in a specific sequence. Workers arrange fibers into subunits, apply a subunit coating, add intermittent bonds between adjacent subunits, and then cure both together. Optical fiber coating application and bond placement must match the ribbon design.
Example designs specify gaps of 5 to 100 micrometers between subunits. A range of 10 to 1,000 millimeters is described for intermittent bond spacing in example designs. Bond deposits may have a diamond-like outline with narrow ends and a broader center. These are disclosed examples, not fixed parameters for every production line.
Ribbon manufacturing process control depends on the chosen materials, bond layout, and curing method. The source material does not specify line speeds, curing temperatures, or inspection intervals, so these values must not be assumed.
Materials, Bond Design, And Ribbon Flexibility
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
Because subunit coatings and ribbon bonding materials serve separate roles, they do not have to share the same formula. Resins that mix or remain at least partly soluble can form a gradual interface. Lower coating viscosity may also promote intermixing.
A diffusion zone forms at this interface, with properties that vary gradually. Differences in colour, stiffness, surface friction, tear strength, or stretch may occur within this zone. Disclosed thicknesses range 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. Intermittent bond geometry provides unbonded spans between bond points. Some bond surfaces have a saddle shape made by intersecting convex and concave curves.
Balance Ribbon Flexibility With Fiber Organization
Between bonds, unbonded spans let a flat ribbon transform into a rolled, curled, or folded form. During cable installation, a flexible fiber ribbon can flex without disrupting the fiber organization needed 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. However, it does not establish inspection methods or acceptance limits.
Check Bond Continuity And Subunit Alignment
Check that intermittent bonds connect adjacent subunits at planned locations and leave unbonded lengths between connections. Review subunit alignment and gaps because shifts can affect ribbon shape and bond geometry.
Evaluate Ribbon Flexibility And Rollability
Assess ribbon rollability by observing how the ribbon bends and gathers without changing fiber order. Throughout the ribbon design, compare bond spacing and flexibility. Treat these comparisons as design checks rather than universal production tolerances.
Confirm 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.
Applications, Cable Integration, And Splicing Benefits
By folding within a cable, intermittently bonded ribbons allow more fibers in a compact design. Prysmian says FlexRibbon supports high-density ribbon cable designs, smaller diameters, and better 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 uses 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.
Enable Mass-Fusion Splicing And Faster Deployment
Multiple ribbon fibers, often 12 at a time, are joined in one operation through mass-fusion splicing. This approach may shorten splice time where ribbon routes are compatible. 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
Ribbon cable is used in 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 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. The materials create a diffusion zone before curing together. Reliable fiber cable manufacturing is encouraged by careful control at every stage.
Mass-fusion ribbon splicing is also supported by flexible ribbons, helping crews splice many fibers in one operation. 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 balance fiber alignment, bond strength, and rollability. This balance may make cable packaging easier while ensuring ribbons remain prepared for efficient installation and splicing.
