An improved optical fibre ribbon structure

Claim 2

An optical fibre ribbon structure comprising a plurality of optical fibres (1) and at least one flexible elongate reinforcing element (2) of substantially resilient material arranged side by side and embedded in an elongate (3) body of plastics material, wherein the or each resilient reinforcing element is set in such a form that the ribbon structure (11) follows a path of smoothly curved undulations (4) whose axes of curvature lie transverse to the longitudinal axis of the ribbon structure, the arrangement being such that, when the undulating ribbon structure is subjected to a tensile force, the ribbon structure straightens in a lengthwise direction against the action of the undulating resilient reinforcing element or elements thereby reducing the tensile force applied to the optical fibres and when the tensile force is removed, the ribbon structure returns towards its original undulating form.

Claim 3

An optical fibre ribbon structure as claimed in Claim 1, wherein the axes of curvature of the undulations lie parallel to one another and substantially normal to the longitudinal axis of the optical fibre ribbon structure.

Claim 4

An optical fibre ribbon structure as claimed in Claim 1 or 2, which includes two or more than two flexible elongate reinforcing elements (2) of substantially .resilient material uniformly spaced across the width of the ribbon structure.

Claim 5

An optical fibre ribbon structure as claimed in Claim 3, which includes two flexible elongate reinforcing elements (2) of substantially resilient material, the separate optical fibres (1) being arranged side by side therebetween.

Claim 6

A method of manufacturing an undulating optical fibre ribbon structure as claimed in Claim 1, which method comprises causing a plurality of separate optical fibres (1) and at least one flexible elongate reinforcing element (2) of substantially resilient material to travel substantially side by side in the directions of their lengths with their axes lying in a substantially common plane; applying to the advancing optical fibres and to the advancing resilient reinforcing element or elements an overall coating (13) of a plastics material to form a plastics- coated reinforced optical fibre array (14); feeding the plastics-coated reinforced optical fibre array between a pair of advancing tapes (15); subjecting the advancing taped plastics-coated reinforced optical fibre array (18) to a curing operation to cure the plastics material and cause it to bond both to the embedded optical fibres and resilient reinforcing element or elements and lightly to the tapes; peeling the tapes away from the reinforced optical fibre array to form a reinforced optical fibre ribbon structure (11); and, before or after the tapes have been peeled away, causing the advancing ribbon structure to be partially wrapped around each of a plurality of transversely extending, longitudinally spaced formers (22) of substantially circular or partially circular cross-section travelling in the same direction as the advancing ribbon structure and at such a speed that there is substantially no relative movement between the advancing formers and the ribbon structure travelling therebetween, the direction of wrap around one former being in the opposite circumferential direction to the direction of wrap around the or each adjacent former and the circumferential extent of wrap around each of the formers being such that the or each resilient reinforcing element is set in such a form that the optical fibre ribbon structure follows a path of smoothly curved undulations (4) whose axes of curvature lie transverse to the longitudinal axis of the ribbon structure.

Claim 7

A method as claimed in Claim 5, wherein the advancing optical fibre ribbon structure is caused to pass between two sets of transversely extending, longitudinally spaced formers (22) carried on a pair of advancing endless belts, the formers on one belt inter-engaging between the formers on the other belt.

Claim 8

A method as claimed in Claim 5 or 6 in which the or each resilient reinforcing element (2) is of metal or metal alloy, wherein the set in the resilient reinforcing element is mechanically formed by causing the advancing optical fibre ribbon structure to be partially wrapped around each of the plurality of formers which are of such diameter and so spaced apart and staggered with respect to the rectilinear axis of the advancing ribbon structure that the resilient reinforcing element is deformed beyond its elastic limit.

Claim 9

A method as claimed in Claim 5 or 6 in which the or each resilient reinforcing element (2) is of a non-metallic resilient material, wherein the set in the resilient reinforcing element is thermally formed by heating the advancing optical fibre ribbon structure upstream of the plurality of transversely extending, longitudinally spaced formers and, as the optical fibre ribbon structure is passing through the plurality of formers, cooling the ribbon structure to such an extent that undulations having the desired radius of curvature are set in the or each resilient reinforcing element.

Claim 10

An optical cable having an outer sheath (34) of plastics material and having, extending throughout its length, at least one bore (31) in which is loosely housed at least one undulating optical fibre ribbon structure (11) as claimed in any one of Claims 1 to 4.

Claim 11

An optical cable as claimed in Claim 9, wherein the or each bore loosely housing an undulating optical fibre ribbon structure is substantially filled throughout its length with a water-impermeable medium of such a consistency that the or each undulating optical fibre ribbon structure is free to move relative to the wall of the bore in which it is loosely housed.