Production of optical fiber cables

Claim 2

A process for the production of optical fiber cables which comprises: (a) surface coating an elongate optical fiber with an elastomer having a high coefficient of thermal expansion; (b) applying to the elastomer a settable resin having a low coefficient of thermal expansion to form an outer resin shell surrounding said elastomer coated optical fiber, the ratio coefficients of thermal expansion of the elastomer coating to said resin being from about 3:1 to about 30:1; (c) setting the applied resin forming the shell when said elastomer is in a thermally expanded state to form a resultant optical fiber cable having a solidified resin shell surrounding a thermally expanded elastomer coating; and (d) cooling the resultant optical fiber cable to contract by the differential of coefficients of thermal expansion of said solidified resin shell and elastomer coating, the elastomer coating more than the resin shell to remove compressive loads from optical fiber.

Claim 3

A process as claimed in claim 1 in which the optical fiber is surface coated with the elastomer to a thickness of at least about 3 mil.

Claim 4

A process as claimed in claim 1 in which the optical fiber is surface coated with the elastomer to a thickness of from about 5 to about 10 mil.

Claim 5

A process as claimed in claim 1 in which the binding resin is a thermosetting resin and set by curing of the thermosetting resin.

Claim 6

A process for the production of optical fiber cables which comprises: (a) providing a core of at least one optical fiber having an annular coating of an elastomer having a high coefficient of thermal expansion; (b) heating the coating to a temperature sufficient to thermally expand said elastomer coating and applying to said thermally expanded elastomer coated core a settable resin having a low coefficient of thermal expansion to form a resin shell surrounding said thermally expanded elastomer core, the ratio of coefficients thermal expansion of the elastomer to the resin when in a set state being from about 3:1 to about 30:1; (c) solidifying the applied resin to a set state while maintaining said elastomer of said core in the thermally expanded state to form a resultant optical fiber cable; and (d) cooling the resultant optical fiber cable to contract by differential of coefficients of thermal expansion of said solidified resin shell and elastomer coating, the elastomer coating more than the shell to remove compressive loads from said optical fiber.

Claim 7

A process for the production of optical fiber cables which comprises: (a) providing a core of at least one optical fiber having an annular coating of an elastomer having a high coefficient of thermal expansion; (b) heating the coating to a temperature sufficient to thermally expand said elastomer coating and applying to said thermally expanded elastomer coated core a settable resin having a low coefficient of thermal expansion to form a resin shell surrounding said thermally expanded elastomer core, the ratio of coefficients thermal expansion of the elastomer to the resin when in a set state being from about 3:1 to about 30:1; (c) solidifying the applied resin to a set state while maintaining said elastomer of said core in the thermally expanded state to form a resultant optical fiber cable; and (d) cooling the resultant optical fiber cable to contract by differential of coefficients of thermal expansion of said solidified resin shell and elastomer coating, the elastomer coating more than the shell to remove compressive loads from said optical fiber.

Claim 8

A process as claimed in claim 5 in which the elastomer coating on the optical fiber has a thickness of at least about 3 mil.

Claim 9

A process as claimed in claim 5 in which the elastomer coating on the optical fiber has a thickness of from about 5 to about 10 mil.

Claim 10

A process as claimed in claim 5 in which the binding resin is a thermosetting resin and set by curing of the thermosetting resin.

Claim 11

A process for the production of optical fiber cables which comprises: (a) surface coating an elongate optical fiber with a curable silicone rubber having a high coefficient of thermal expansion; (b) curing said silicone rubber coating; (c) applying to the cured silicone rubber coated optical fiber a plurality of reinforcing fibers and a binding resin to form a fiber reinforced resin shell surrounding said coated optical fiber, said binding resin and reinforcing fibers in combination and in a resin set state, having a coefficient of thermal expansion less than the coefficient of thermal expansion of said cured silicone rubber coating; (d) setting the binding resin of said fiber reinforced shell when said cured silicone rubber is in the thermally expanded state to form a resultant optical fiber cable having a solidified fiber reinforced shell; and (e) cooling the resultant fiber reinforced cable to contract by the differential of coefficients of thermal expansion of said solidified shell and silicone rubber coating, the silicone rubber coating more than the shell to remove compressive loads from said optical fiber.

Claim 12

A process for the production of optical fiber cables which comprises: (a) surface coating an elongate optical fiber with a curable silicone rubber having a high coefficient of thermal expansion; (b) curing said silicone rubber coating; (c) applying to the cured silicone rubber coated optical fiber a plurality of reinforcing fibers and a binding resin to form a fiber reinforced resin shell surrounding said coated optical fiber, said binding resin and reinforcing fibers in combination and in a resin set state, having a coefficient of thermal expansion less than the coefficient of thermal expansion of said cured silicone rubber coating; (d) setting the binding resin of said fiber reinforced shell when said cured silicone rubber is in the thermally expanded state to form a resultant optical fiber cable having a solidified fiber reinforced shell; and (e) cooling the resultant fiber reinforced cable to contract by the differential of coefficients of thermal expansion of said solidified shell and silicone rubber coating, the silicone rubber coating more than the shell to remove compressive loads from said optical fiber.

Claim 13

A process as claimed in claim 9 in which the reinforcing fibers are axially aligned with the optical fiber.

Claim 14

A process as claimed in claim 9 in which the optical fiber is surface coated to a thickness of at least about 3 mil.

Claim 15

A process as claimed in claim 9 in which the optical fiber is surface coated to a thickness of from about 5 to about 10 mil.

Claim 16

A process as claimed in claim 9 in which the cured silicone rubber is in a thermally expanded state by maintaining the silicone rubber at a temperature of from about 300° to about 400° F. when the binding resin of the fiber reinforced resin is set.

Claim 17

A process as claimed in claim 13 in which the binding resin is a thermosetting resin and set by curing of the thermosetting resin.

Claim 18

A process for the production of optical fiber cables which comprises: (a) providing a core of at least one optical fiber having an annular coating of a cured silicone rubber having a high coefficient of thermal expansion; (b) heating the coating to a temperature sufficient to thermally expand said silicone rubber coating and applying to said thermally expanded coating core a plurality of reinforcing fibers and a resin binder for said reinforcing fibers to form a fiber reinforced shell surrounding said core, the thermal coefficient of the combination of the reinforcing fiber and resin binder having a coefficient of thermal expansion, when the resin is in a set state, substantially less than the coefficient of thermal expansion of said cured silicone rubber; (c) solidifying the resin binder while maintaining said silicone rubber of said core in the thermally expanded state to form a resultant fiber reinforced cable; and (d) cooling the resultant fiber reinforced cable to contract by the differential of coefficients of thermal expansion of said solidified shell and silicone rubber coating, the silicone rubber coating more than the shell to remove compressive loads from said optical fiber.

Claim 19

A process for the production of optical fiber cables which comprises: (a) providing a core of at least one optical fiber having an annular coating of a cured silicone rubber having a high coefficient of thermal expansion; (b) heating the coating to a temperature sufficient to thermally expand said silicone rubber coating and applying to said thermally expanded coating core a plurality of reinforcing fibers and a resin binder for said reinforcing fibers to form a fiber reinforced shell surrounding said core, the thermal coefficient of the combination of the reinforcing fiber and resin binder having a coefficient of thermal expansion, when the resin is in a set state, substantially less than the coefficient of thermal expansion of said cured silicone rubber; (c) solidifying the resin binder while maintaining said silicone rubber of said core in the thermally expanded state to form a resultant fiber reinforced cable; and (d) cooling the resultant fiber reinforced cable to contract by the differential of coefficients of thermal expansion of said solidified shell and silicone rubber coating, the silicone rubber coating more than the shell to remove compressive loads from said optical fiber.

Claim 20

A process as claimed in claim 15 in which the reinforcing fibers are axially aligned with the optical fiber.

Claim 21

A process as claimed in claim 15 in which the optical fiber is surface coated to a thickness of at least about 3 mil.

Claim 22

A process as claimed in claim 15 in which the optical fiber is surface coated to a thickness of from about 5 to about 10 mil.

Claim 23

A process as claimed in claim 15 in which the cured silicone rubber is in a thermally expanded state by maintaining the silicone rubber at a temperature of from about 300° to about 400° F. when the binding resin of the fiber reinforced resin is set.

Claim 24

A process as claimed in claim 19 in which the binding resin is a thermosetting resin and set by curing of the thermosetting resin.