Guide To The Intermittent Bonded Ribbon Production Line
An intermittent bonded ribbon production line joins fiber subunits at set intervals. This maintains fibers in an organized arrangement for mass-fusion splicing while letting the ribbon roll or fold into a compact cable shape. The design enables flexible ribbon cable production without compromising effective fiber handling.
In some processes, bonding material is added while the subunit coating is still uncured. Diffusion can occur across the shared interface before the materials cure together. One commercial example is Prysmian’s FlexRibbon technology, whose original design the company says dates 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.
How Fiber Subunits And Intermittent Bonds Are Arranged
Each adjacent pair or group of fibers is held together by a coating. These optical fiber subunits connect to neighboring subunits at spaced bond points rather than along their full length. Six two-fiber subunits may make up 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
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 curl without losing the fiber alignment needed for mass-fusion splicing. Prysmian’s FlexRibbon uses compact bonding points to permit bending and folding.
Why Flexible Ribbons Support Compact, High-Density Cables
Inside a high-density fiber cable, a flexible ribbon can take up less space. This enables cable designers to fit more fibers into a compact structure while maintaining an organized fiber layout.
Process And Equipment For An Intermittent Bonded Ribbon Production Line
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 spaced points with a second material, leaving flexible sections between bonds.
Organize Adjacent Optical Fibers Into Subunits
The planned ribbon layout determines how fibers are arranged next to one another. Each selected group becomes a subunit when the first coating material surrounds and holds its fibers together.
Apply Subunit Coating And Intermittent Bonding Material
The subunits are created by fiber ribbon coating. A discrete coating applicator places bonding material between neighboring subunits at intervals rather than along their entire length.
Create Diffusion Zones Through Wet-On-Wet Application
During wet-on-wet bonding, the subunit coating remains unset when bonding material is applied. A diffusion zone develops as the materials diffuse through their shared interface.
Cure The Subunit Coating And Bonds Together
A single curing step sets 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 Operation | Purpose |
|---|---|---|
| Optical fiber arrangement | Arrange fibers next to one another | Establish the ribbon layout |
| Subunit formation | Apply the first coating material around fiber groups | Hold two or more fibers as subunits |
| Bonding at intervals | Deposit the second material between neighboring subunits | Connect subunits at separated bond points |
| Wet-on-wet interface | Deposit bonds while the subunit coating remains uncured | Allow materials to form a diffusion zone |
| Joint curing step | Set the coating and bonds together in one step | Cure the assembled ribbon structure |
Key Production Line Stages And Process Controls
The fiber ribbon production stages follow a defined order. The sequence involves organizing 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 given in example designs. Example intermittent bond spacing ranges from 10 to 1,000 millimeters. Some bond deposits take a diamond-like shape, narrowing at the ends and widening in the center. These are disclosed examples, not fixed settings for every production line.
The selected materials, bond layout, and curing method influence ribbon manufacturing process control. The source material does not specify line speeds, curing temperatures, or inspection intervals, so these values must not be inferred.
Materials, Bond Design, And Ribbon Flexibility
Ribbon behavior during cable making and splicing depends on the chosen materials and bond layout. Coatings shield 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 produce a gradual interface. Lower coating viscosity may also promote intermixing.
This interface creates a diffusion zone in which properties change gradually. The zone may differ in color, stiffness, surface friction, tear strength, or stretch. Disclosed thicknesses range from 2 to 50 micrometers, with 5 to 15 micrometers representing a narrower range.
Manage Bond Placement, Spacing, And Geometry
Where subunits remain joined or move freely is governed by bond spacing. Intermittent bond geometry leaves unbonded spans between 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 focus on defined features. The patent identifies design factors such as bond spacing, subunit gaps, diffusion-zone thickness, and bond shape. The patent does not, however, define inspection methods or acceptance limits.
Check Bond Continuity And Subunit Alignment
Check that intermittent bonds join 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 examining how the ribbon bends and gathers without changing fiber order. Throughout the ribbon design, compare bond spacing and flexibility. These comparisons are design checks, not universal production tolerances.
Confirm Fiber Identification And Ribbon Configuration
Use fiber color coding to confirm the position of each fiber. A common 12-color sequence is blue, orange, green, brown, slate, white, red, black, yellow, violet, rose, and aqua. 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. According to Prysmian, FlexRibbon enables high-density ribbon cable designs with smaller diameters and better fiber duct utilization.
Enable High-Density Cable Designs And Better Duct Utilization
For indoor, outdoor, and indoor/outdoor applications, Prysmian offers FusionLink and MassLink with FlexRibbon. Dry water blocking is used in FusionLink, which comes with either 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 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
Applications for ribbon cable include 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 align cable construction with the needs of buildings, aerial runs, and underground installations.
Conclusion
An intermittent bonded ribbon line guide brings together 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 applied before the subunit coating cures. Before they cure together, the materials form a diffusion zone. Careful control throughout the process helps maintain reliable fiber cable manufacturing.
Mass-fusion ribbon splicing is also enabled by flexible ribbons, helping crews splice many fibers in one operation. Prysmian describes FlexRibbon in various cable designs, including compact configurations containing up to 6,912 fibers.
For manufacturers and network planners, the priority is to coordinate fiber alignment, bond strength, and rollability. This balance may make cable packaging simpler while ensuring ribbons remain prepared for efficient installation and splicing.
