Guide To The Intermittent Bonded Ribbon Production Line
An intermittent bonded ribbon production line connects fiber subunits at set intervals. Fibers remain organized for mass-fusion splicing, while the ribbon can fold into a compact cable shape. Flexible ribbon cable production is supported by this design while preserving efficient fiber handling.
Some processes apply bonding material before the subunit coating cures. Diffusion can occur across the shared interface before the materials 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.
Intermittent Bonded Ribbon Production Line Fibers In Stainless Steel Tube Compact Fiber Unit
What Is An Intermittent Bonded Fiber Ribbon?
An intermittent bonded fiber ribbon groups optical fibers into small subunits. Although they remain organized for splicing, the subunits can change their shape to fit within 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. A 12-fiber design may include six two-fiber subunits. 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
In a conventional flat ribbon, the fibers remain in one fixed plane. A rollable fiber ribbon can fold between bonds while retaining fiber alignment 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
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 preserving an organized fiber layout.
Intermittent Bonded Ribbon Production Line: Process And Equipment
Throughout an intermittent bonded ribbon production process, optical fibers are laid side by side along the ribbon’s length. A first material coats groups of two or more fibers to form subunits. A second material links neighboring subunits at spaced points and leaves flexible sections between the bonds.
Arrange Adjacent Optical Fibers Into Subunits
The planned ribbon layout determines how fibers are positioned next to one another. Each selected group becomes a subunit when the first coating material encases and holds its fibers together.
Deposit Subunit Coating And Intermittent Bonding Material
Fiber ribbon coating creates the subunits. Bonding material is applied 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
During wet-on-wet bonding, the subunit coating remains uncured when bonding material is applied. The materials intermix across their shared interface to form a diffusion zone.
Cure The Subunit Coating And Bonds Together
Both the subunit coating and the intermittent bonds are set in one curing step. Although optical fiber ribbon equipment is used for these operations, the complete equipment list, line speed, and production capacity are not provided.
| Process Stage | Material Or Action | Intended Purpose |
|---|---|---|
| Fiber arrangement | Place fibers side by side | Set the ribbon layout |
| Formation of subunits | Coat fiber groups with the first coating material | Hold two or more fibers as subunits |
| Intermittent bonding | Deposit the second material between neighboring 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 |
| Combined cure | 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 set sequence. The sequence involves organizing fibers into subunits, applying a subunit coating, placing intermittent bonds between adjacent subunits, and curing the coating and bonds together. The ribbon design must guide both optical fiber coating application and placement of the bonds.
Example designs specify gaps of 5 to 100 micrometers between subunits. 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.
Ribbon manufacturing process control depends on the chosen material selection, 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 the chosen materials and bond layout. Coatings shield each fiber while permitting the subunits to flex as intended.
Choose Compatible Coating And Bonding Materials
Because subunit coatings and ribbon bonding materials serve separate roles, they do not have to share the same formula. A gradual interface can be created by resins that intermix or remain at least partly soluble. Lower coating viscosity may also promote intermixing.
This interface forms a diffusion zone in which properties change gradually. The zone may differ in color, stiffness, surface friction, tear strength, or stretch. The disclosed thickness range is 2 to 50 micrometers, while 5 to 15 micrometers is given as a narrower range.
Manage Bond Placement, Spacing, And Geometry
Bond spacing determines where fiber subunits stay connected and where they can move freely. Intermittent bond geometry provides unbonded spans between bond points. Some bond surfaces have a saddle shape made by intersecting convex and concave curves.
Maintain Fiber Organization While Balancing Ribbon Flexibility
Unbonded spans allow the ribbon to change from a flat layout into a rolled, curled, or folded shape. A flexible fiber ribbon design flexes during cable installation while keeping fibers organized for splicing.
Quality Checks For Consistent Ribbon Production
Reliable fiber ribbon quality checks evaluate defined features rather than relying on assumed pass limits. The patent identifies design factors such as bond spacing, subunit gaps, diffusion-zone thickness, and bond shape. However, it does not specify inspection methods or acceptance limits.
Check Bond Continuity And Subunit Alignment
Verify that intermittent bonds join adjacent subunits at the planned positions, with unbonded lengths between them. Review subunit alignment and gaps because shifts can affect ribbon shape and bond geometry.
Assess Ribbon Flexibility And Rollability
To evaluate ribbon rollability, watch whether it bends and gathers while keeping fibers in their original order. Throughout the ribbon design, compare bond spacing and flexibility. These comparisons are checks of the design, not universal production tolerances.
Confirm Fiber Identification And Ribbon Configuration
Confirm each fiber’s position through fiber color coding. 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.
Cable Applications, 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 improved fiber duct utilization.
Enable High-Density Cable Designs And Better Duct Utilization
Prysmian offers FusionLink and MassLink with FlexRibbon in indoor, outdoor, and indoor/outdoor designs. FusionLink features 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 reduce splice time where ribbon routes are compatible. For loose-tube cable connections, technicians separate the ribbon fibers and splice them one by one using a single-fiber splicer.
Review Indoor, Outdoor, Access, And Broadband Applications
Applications for ribbon cable include point-to-point network links, indoor FTTH systems, MTP wiring-box links, and urban trunk routes. Choosing indoor and outdoor fiber cable to suit the route matches its construction with building, aerial, and underground requirements.
Final Conclusions
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 develop a diffusion zone. Careful control throughout the process supports reliable fiber cable manufacturing.
Flexible ribbons also facilitate mass-fusion ribbon splicing, allowing crews to join multiple fibers at once. FlexRibbon is described by Prysmian as suitable for multiple cable designs, including compact configurations with up to 6,912 fibers.
Manufacturers and network planners need to manage fiber alignment, bond strength, and rollability. This balance may make cable packaging simpler while ensuring ribbons remain prepared for efficient installation and splicing.