Intermittent Bonded Ribbon Production Line Guide
An intermittent bonded ribbon production line joins fiber subunits at set intervals. Fibers remain organized for mass-fusion splicing, while the ribbon can roll into a compact cable shape. Flexible ribbon cable production is supported by this design while preserving efficient 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. Prysmian’s FlexRibbon technology provides one commercial example, and the company dates its original design to 2018. Together, these methods demonstrate the connection between optical fiber ribbon manufacturing and fiber optic bonding.
Intermittent Bonded Ribbon FTTH Cable Production Line Compact Fiber Unit
Understanding What An Intermittent Bonded Fiber Ribbon Is
Optical fibers are arranged into small subunits in an intermittent bonded fiber ribbon. The subunits stay organized for splicing while remaining able to change shape to fit inside a cable.
How Fiber Subunits And Intermittent Bonds Are Arranged
Each neighboring pair or group of fibers is held together by a coating. Instead of joining along their entire length, these optical fiber subunits are linked to neighboring subunits at spaced bond points. Six two-fiber subunits may form 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
In a conventional flat ribbon, the fibers remain in one fixed plane. A rollable fiber ribbon can curl between bonds while retaining fiber alignment for mass-fusion splicing. Prysmian’s FlexRibbon uses small bonding points to permit bending and folding.
How Flexible Ribbons Enable Compact, High-Density Cables
Ribbon flexibility limits the space it occupies inside a high-density fiber cable. 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
The intermittent bonded ribbon production process places optical fibers side by side along the ribbon’s length. Subunits are formed when a first material coats groups containing two or more fibers. Neighboring subunits are joined at spaced points with a second material, leaving flexible sections between bonds.
Organize Adjacent Optical Fibers Into Subunits
Fibers are placed beside one another according to the planned ribbon layout. The first coating material encloses each selected group and holds its fibers together as a subunit.
Apply Subunit Coating And Intermittent Bonding Material
The subunits are created by fiber ribbon coating. Bonding material is deposited by a discrete coating applicator between neighboring subunits at spaced intervals, not continuously along their full length.
Use Wet-On-Wet Application To Form Diffusion Zones
During wet-on-wet bonding, the subunit coating remains unset when bonding material is applied. A diffusion zone develops as the materials intermix through their shared interface.
Cure The Subunit Coating And Bonds Together
Both the subunit coating and the intermittent bonds are cured in one curing step. Optical fiber ribbon equipment performs these operations, although a complete equipment list, line speed, and production capacity are not specified.
| Production Stage | Material Or Operation | Intended Purpose |
|---|---|---|
| Optical fiber arrangement | Place fibers side by side | Set the ribbon layout |
| Subunit formation | Apply the first coating material around fiber groups | Keep groups of two or more fibers together as subunits |
| Bonding at intervals | Apply the second material between adjacent subunits | Join subunits at spaced points |
| Wet-on-wet bonding interface | Deposit bonds while the subunit coating remains uncured | Allow materials to form a diffusion zone |
| Combined cure | Set the coating and bonds together in one step | Set 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 positioning of the bonds.
Gaps of 5 to 100 micrometers between subunits are described in example designs. A range of 10 to 1,000 millimeters is described for intermittent bond spacing in example designs. Bond deposits may have a diamond-like outline with narrow ends and a wider center. The disclosed examples should not be interpreted as fixed settings that apply to every line.
Ribbon manufacturing process control depends on the chosen material selection, bond layout, and curing method. Because the source material provides no line speeds, curing temperatures, or inspection intervals, avoid assuming any values for them.
Ribbon Flexibility, Bond Design, And Materials
Ribbon behavior during cable making and splicing depends on the chosen materials and bond layout. Each fiber is protected by coatings that still allow the subunits to flex as designed.
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. Intermixing may also be increased by lower coating viscosity.
A diffusion zone forms at this interface, with properties that vary gradually. Differences in color, stiffness, surface friction, tear strength, or stretch may occur within this zone. 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 create the saddle shape used on some bond surfaces.
Maintain Fiber Organization While Balancing Ribbon Flexibility
Between bonds, unbonded spans let a flat ribbon move into a rolled, curled, or folded form. A flexible fiber ribbon design flexes during cable installation while keeping fibers organized for splicing.
Quality Checks For Consistent Ribbon Production
Instead of using assumed pass limits, dependable fiber ribbon quality checks assess defined features. Design factors named in the patent include the spacing of bonds, subunit gaps, diffusion-zone thickness, and bond shape. However, it does not establish inspection methods or acceptance limits.
Check Bond Continuity And Subunit Alignment
Verify that intermittent bonds join adjacent subunits at the intended positions, with unbonded lengths between them. Subunit alignment and gaps require checking because shifts may change ribbon shape and bond geometry.
Assess Ribbon Flexibility And Rollability
To evaluate ribbon rollability, observe whether it bends and gathers while keeping fibers in their original order. Compare bond spacing and flexibility across the entire ribbon design. Treat these comparisons as design checks rather than universal production tolerances.
Confirm Fiber Identification And Ribbon Configuration
Use fiber color coding to confirm the position of each fiber. Blue, orange, green, brown, slate, white, red, black, yellow, violet, rose, and aqua make up a common 12-color sequence. The color sequence may repeat when a ribbon has more than 12 fibers.
Applications, Cable Integration, And Splicing Benefits
Intermittently bonded ribbons can roll inside a cable, enabling more fibers to fit into a compact design. According to Prysmian, FlexRibbon enables high-density ribbon cable designs with smaller diameters and better fiber duct utilization.
Support High-Density Cable Designs And 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. Under NESC Heavy loading conditions, EcoSpan aerial cable can support spans of up to 300 feet. As a small-diameter outdoor option, FlexDrop can support 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. On compatible ribbon routes, this method can shorten splice time. 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.
Conclusion
An intermittent bonded ribbon line guide covers 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.
Mass-fusion ribbon splicing is also enabled by flexible ribbons, helping crews splice many fibers in one operation. 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. Achieving that balance can simplify cable packaging while keeping ribbons ready for efficient installation and splicing.