US4508423A — Method and apparatus for assembling an optical fi…

Claim 1

Independent Claim 82 words

An apparatus for assembling an optical fiber communication cable, said apparatus comprising: die means for forming a tubular member having a substantially downwardly facing seam from a strip of metal or metal alloy; means for soldering said substantially downwardly facing tubular member seam to provide a sealed tubular member; and means for depositing at least one optical fiber into said sealed tubular member after said seam has been soldered, said depositing means protecting said at least one optical fiber during said soldering.

Claim 2

Independent Claim 82 words

An apparatus for assembling an optical fiber communication cable, said apparatus comprising: die means for forming a tubular member having a substantially downwardly facing seam from a strip of metal or metal alloy; means for soldering said substantially downwardly facing tubular member seam to provide a sealed tubular member; and means for depositing at least one optical fiber into said sealed tubular member after said seam has been soldered, said depositing means protecting said at least one optical fiber during said soldering.

Claim 3

Dependent Claim 36 words

The apparatus of claim 1 further comprising: said depositing means including means for depositing a cushioning material into said sealed tubular member after said soldering has been completed, said cushioning material surrounding each said optical fiber.

Claim 4

Dependent Claim 29 words

The apparatus of claim 2 wherein said depositing means comprises means for depositing said cushioning material into said sealed tubular member before inserting said at least one optical fiber.

Claim 5

Dependent Claim 31 words

The apparatus of claim 2 wherein said depositing means comprises means for substantially simultaneously inserting said at least one optical fiber and injecting said cushioning material into said sealed tubular member.

Claim 6

Dependent Claim 27 words

The apparatus of claim 4 wherein said depositing means comprises a single passageway through which both said cushioning material and said at least one optical fiber pass.

Claim 7

Dependent Claim 69 words

The apparatus of claim 2 wherein said depositing means comprises: a first passageway through which said at least one optical fiber passes, said first passageway having a first outlet through which said at least one optical fiber passes into said tubular member; and a second passageway through which said cushioning material flows, said second passageway having a second outlet through which said cushioning material flows into said tubular member.

Claim 8

Dependent Claim 48 words

The apparatus of claim 6 further comprising: said first and second passageways having different lengths; and said first and second outlets being arranged so that said cushioning material flows into said tubular member upstream of the insertion of said at least one optical fiber into said tubular member.

Claim 9

Dependent Claim 20 words

The apparatus of claim 2 further comprising: said depositing means extending into said tubular member downstream of said soldering means.

Claim 10

Dependent Claim 19 words

The apparatus of claim 1 further comprising: said depositing means extending into said tubular member downstream of soldering means.

Claim 11

Dependent Claim 47 words

The apparatus of claim 1 further comprising: said depositing means being fabricated from a material that is unbondable to said tubular member and that has a relatively low thermal conductivity, whereby heat created during said soldering operation does not adversely affect said at least one optical fiber.

Claim 12

Dependent Claim 23 words

The apparatus of claim 10 wherein said material is selected from the group consisting of refractory alloys, stainless steels, ceramics and insulating materials.

Claim 13

Dependent Claim 45 words

The apparatus of claim 10 wherein said material comprises a composite material, said composite material having an outer layer comprising a first material with a relatively low thermal conductivity and an inner layer comprising a second material with a conductivity higher than said first material.

Claim 14

Dependent Claim 49 words

The apparatus of claim 1 wherein said soldering means comprises: a source of solder; and solder head means for forming a spout of solder so that as said tubular member and said seam pass over said spout, said solder capillaries into said seam and thereby seals said tubular member.

Claim 15

Dependent Claim 37 words

The apparatus of claim 1 further comprising: means for fabricating a dielectric layer around said member; means for fabricating a loadbearing layer around said dielectric layer; and means for fabricating an outer covering around said loadbearing layer.

Claim 16

Dependent Claim 13 words

The apparatus of claim 1 further comprising: means for cooling said depositing means.

Claim 17

Dependent Claim 26 words

The apparatus of claim 1 further comprising: means for applying flux to edges of said strip prior to said strip being formed into said tubular member.

Claim 18

Dependent Claim 24 words

The apparatus of claim 1 wherein said depositing means comprises means for depositing each said fiber into said tubular member in an unconstrained manner.

Claim 19

Dependent Claim 22 words

The apparatus of claim 1 wherein said depositing means comprises means for depositing a plurality of said fibers into said tubular member.

Claim 20

Dependent Claim 80 words

An optical fiber communication cable comprising: a drawn high strength copper alloy tube having a generally longitudinally extending seam, said seam being formed generally facing downwardly and having edges in relatively close proximity; a solder material substantially filling said seam and bonding said generally downwardly facing edges together for providing a substantially sealed tube; and at least one optical fiber within said tube, said at least one optical fiber being inserted into said tube after said solder material has solidified.

Claim 21

Dependent Claim 80 words

An optical fiber communication cable comprising: a drawn high strength copper alloy tube having a generally longitudinally extending seam, said seam being formed generally facing downwardly and having edges in relatively close proximity; a solder material substantially filling said seam and bonding said generally downwardly facing edges together for providing a substantially sealed tube; and at least one optical fiber within said tube, said at least one optical fiber being inserted into said tube after said solder material has solidified.

Claim 22

Dependent Claim 32 words

The cable of claim 19 further comprising: a cushioning material located within said tube, said cushioning material substantially surrounding said at least one optical fiber; and said tube forming an electrical conductor.

Claim 23

Dependent Claim 15 words

The cable of claim 20 further comprising: at least one external layer surrounding said tube.

Claim 24

Independent Claim 87 words

An apparatus for assembling an optical fiber communication cable, said apparatus comprising: die means for forming a tubular member having a substantially downwardly facing seam from a strip of metal or metal alloy; means for substantially filling said substantially downwardly facing seam with a sealing material to form a sealed tubular member; and means for depositing at least one optical fiber into said sealed tubular member after said seam has been substantially filled, said depositing means protecting said at least one optical fiber during said seam filling.

Claim 25

Independent Claim 87 words

An apparatus for assembling an optical fiber communication cable, said apparatus comprising: die means for forming a tubular member having a substantially downwardly facing seam from a strip of metal or metal alloy; means for substantially filling said substantially downwardly facing seam with a sealing material to form a sealed tubular member; and means for depositing at least one optical fiber into said sealed tubular member after said seam has been substantially filled, said depositing means protecting said at least one optical fiber during said seam filling.

Claim 26

Dependent Claim 15 words

The apparatus of claim 22 wherein said filling means comprises means for soldering said seam.

Claim 27

Dependent Claim 20 words

The apparatus of claim 22 wherein said filling means comprises means for substantially filling said seam with a brazing material.

Claim 28

Independent Claim 90 words

A method of assembling an optical fiber communication cable, said method comprising: providing a strip of metal or metal alloy; providing at least one optical fiber; forming a tubular member having a substantially downwardly facing seam from said strip of metal or metal alloy; soldering said substantially downwardly facing seam to form a sealed tubular member; and depositing said at least one optical fiber into said sealed tubular member after said soldering step has been completed so that the likelihood of damaging said at least one optical fiber is reduced.

Claim 29

Independent Claim 90 words

A method of assembling an optical fiber communication cable, said method comprising: providing a strip of metal or metal alloy; providing at least one optical fiber; forming a tubular member having a substantially downwardly facing seam from said strip of metal or metal alloy; soldering said substantially downwardly facing seam to form a sealed tubular member; and depositing said at least one optical fiber into said sealed tubular member after said soldering step has been completed so that the likelihood of damaging said at least one optical fiber is reduced.

Claim 30

Dependent Claim 49 words

The method of claim 25 further comprising: providing a material for cushioning said at least one optical fiber; and depositing said cushioning material into said sealed tubular member after said soldering step has been completed so that said cushioning material does not adversely affect said soldering of said seam.

Claim 31

Dependent Claim 51 words

The method of claim 26 wherein: said step of depositing said cushioning material into said sealed tubular member occurs prior to said step of depositing said at least one optical fiber into said sealed tubular member so that said cushioning material substantially surrounds and positions said at least one optical fiber.

Claim 32

Dependent Claim 37 words

The method of claim 26 wherein: said step of depositing said cushioning material into said sealed tubular member occurs substantially simultaneously with said step of depositing said at least one optical fiber into said sealed tubular member.

Claim 33

Dependent Claim 30 words

The method according to claim 26 further comprising: heating said cushioning material to increase its flowability prior to said step of depositing said cushioning material into said sealed tubular member.

Claim 34

Dependent Claim 9 words

The product formed by the method of claim 26.

Claim 35

Dependent Claim 29 words

The method of claim 25 wherein said step of forming said tubular member comprises: providing die means for forming said member; and pulling said strip through said die means.

Claim 36

Dependent Claim 39 words

The method of claim 31 further comprising: providing means for applying a flux to edges of said strip; and pulling said strip through said flux applying means prior to said step of pulling said strip through said die means.

Claim 37

Dependent Claim 65 words

The method of claim 25 wherein said step of soldering said seam comprises: providing a source of solder and a soldering head having an orifice; forming a spout of solder by passing said solder through said soldering head and orifice; and passing said tubular member and said downwardly facing seam over said solder spout and causing said solder to flow into said downwardly facing seam.

Claim 38

Dependent Claim 32 words

The method of claim 25 further comprising: fabricating a dielectric layer around said tubular member; fabricating a loadbearing layer around said dielectric layer; and fabricating an outer covering around said loadbearing layer.

Claim 39

Dependent Claim 25 words

The method of claim 25 wherein said step of providing a strip of metal or metal alloy comprises: providing a material consisting essentially of copper.

Claim 40

Dependent Claim 25 words

The method of claim 25 wherein said at least one optical fiber depositing step comprises: depositing a plurality of said fibers into said tubular member.

Claim 41

Dependent Claim 20 words

The method of claim 25 further comprising: depositing each said optical fiber into said tubular member in an unconstrained condition.

Claim 42

Dependent Claim 45 words

The method of claim 25 further comprising: providing capillary means for depositing said at least one fiber into said tubular member and for protecting said at least one fiber during said soldering in its place step; and forming said tubular member about said capillary means.

Claim 43

Dependent Claim 52 words

The method of claim 38 further comprising: forming said capillary means from a material that will not bond to said tubular member during said sealing step and that has a relatively low thermal conductivity so that heat created during said sealing step will not adversely affect said at least one optical fiber.

Claim 44

Dependent Claim 19 words

The method of claim 38 further comprising: flowing a cushioning material through said capillary means into said tubular member.

Claim 45

Dependent Claim 11 words

The method of claim 38 further comprising: cooling said capillary means.

Claim 46

Dependent Claim 17 words

The method of claim 25 wherein said tubular member forming step comprises: forming a tubular electrical conductor.

Claim 47

Dependent Claim 9 words

The product formed by the method of claim 25.

Claim 48

Dependent Claim 35 words

The method of claim 25 wherein said soldering step comprises: providing a source of solder; and passing said tubular member and said seam over said solder source so that said solder substantially fills said seam.

Claim 49

Independent Claim 83 words

A method of assembling an optical fiber communication cable, said method comprising: forming a tubular member having a substantially downwardly facing seam from a strip of metal or metal alloy; substantially filling said substantially downwardly facing seam with a sealing material to form a sealed tubular member; and depositing at least one optical fiber into said sealed tubular member after said seam has been substantially filled so that the likelihood of damaging said at least one optical fiber during cable assembly is reduced.

Claim 50

Independent Claim 83 words

A method of assembling an optical fiber communication cable, said method comprising: forming a tubular member having a substantially downwardly facing seam from a strip of metal or metal alloy; substantially filling said substantially downwardly facing seam with a sealing material to form a sealed tubular member; and depositing at least one optical fiber into said sealed tubular member after said seam has been substantially filled so that the likelihood of damaging said at least one optical fiber during cable assembly is reduced.

Claim 51

Dependent Claim 13 words

The method of claim 45 wherein said filling step comprises soldering said seam.

Claim 52

Dependent Claim 18 words

The method of claim 45 wherein said filling step comprises substantially filling said seam with a brazing material.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1988-04-01	1988-10-01	1989-04-02	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1992-04-01	1992-10-01	1993-04-02	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1996-04-01	1996-10-01	1997-04-02	$7700.00	Window Closed / Lapsed

Method and apparatus for assembling an optical fiber communication cable

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