PRE-TERMINATED OPTICAL FIBRE CABLE ASSEMBLY, METHODS OF MANUFACTURE AND INSTALLATION THEREOF

Abstract

The present invention relates to a pre-terminated (pre-terminated) optical fibre cable assembly (10,90), which is configured to be installed through a duct (20). The pre-terminated optical fibre construction (10,90) includes at least one optical fibre (46). A protective sleeve (26) is added to the optical fibre (46) before adding a terminal connector (24) to the leading end of at least one optical fibre (46). The protective sleeve (26) extends from behind the terminal connector (24) along part of the length of the optical fibre (46). When the cable is installed through a duct, the protective sleeve protects the portion of the fibre that protrudes from the end of the duct, for example in a communications cabinet (16). A residual length (28) of the protective sleeve remains within the duct. Terminal connectors and protective sleeves can be applied at both ends of the cable assembly, or only one end.

Claims

1. A pre-terminated optical fibre cable assembly configured to be installed through a duct, wherein prior to installation the pre-terminated optical fibre cable assembly comprises: at least one optical fibre; a terminal connector on at least a leading end of the at least one optical fibre; and a protective sleeve extending from a position closely behind the terminal connector along a minor part, less than 50% of the length of the optical fibre for protecting the optical fibre where it is vulnerable outside the duct, and where it emerges from the duct after installation through the duct.

2. A The pre-terminated optical fibre cable assembly as claimed in claim 1, wherein a protective layer is provided over the at least one optical fibre and wherein the protective layer extends over a major part of the length of the optical fibre.

3. The pre-terminated optical fibre cable assembly as claimed in claim 2, wherein the cable assembly, including the leading end having the terminal connector and the protective sleeve is adapted for installation into said duct by blowing.

4. The pre-terminated optical fibre cable assembly as claimed in claim 2, wherein the protective layer extends over substantially the full length of the optical fibre.

5. The pre-terminated optical fibre cable assembly as claimed in claim 2 wherein the protective layer comprises a first layer in which the at least one optical fibre is embedded with one or more other optical fibres in said first layer to form an optical fibre bundle, the protective sleeve extending over said optical fibre bundle.

6. The pre-terminated optical fibre cable assembly as claimed in claim 5, wherein the first layer comprises a UV-cured resin.

7. The pre-terminated optical fibre cable assembly as claimed in 5, wherein the optical fibre bundle is surrounded by an outer sheath of extruded material over at least the majority of the length of the optical fibre bundle.

8. The pre-terminated optical fibre cable assembly as claimed in claim 7, wherein the outer sheath extends beneath said protective sleeve along substantially the whole length of the protective sleeve.

9. The pre-terminated optical fibre cable assembly as claimed in claim 7, wherein said outer sheath extends beneath said protective sleeve along only a part of its length.

10. The pre-terminated optical fibre construction as claimed in claim 7, wherein the outer sheath has been removed from the portion of the optical fibre that lies beneath the protective sleeve, and extends from a point behind the protective sleeve over a major part of the length of the optical fibre bundle.

11. A pre-terminated optical fibre cable assembly as claimed in claim 10, wherein the outer sheath abuts the protective sleeve, thereby providing a restraint against movement of the protective sleeve.

12. The pre-terminated optical fibre cable assembly as claimed in claim 3, wherein an outer surface of the protective sleeve is formed by a mixture of a polymer and a friction reducing material.

13. The pre-terminated optical fibre cable assembly as claimed in claim 12, wherein the polymer of the surface of the protective sleeve is primarily HDPE.

14. The pre-terminated cable assembly as claimed in claim 1, wherein the protective sleeve has an outer diameter between 0.5 and 3.5 mm.

15. The pre-terminated cable assembly as claimed in claim 14, wherein the protective sleeve has an outer diameter less than 2.5 mm.

16. The pre-terminated cable assembly as claimed in claim 1, wherein a portion of the cable assembly, including the leading end having the terminal connector and the protective sleeve, is adapted for installation into a duct having an inner bore diameter of approximately 3.5 mm.

17. (canceled)

18. The pre-terminated cable assembly as claimed claim 1, comprising a duplex terminal connector, wherein two terminal connectors are connected to two optical fibres, each terminal connector comprising a ferrule body, the ferrule body being adapted to be received in a connector body after installation, and wherein a portion of the cable assembly, including the leading end having the terminal connector and the protective sleeve, is adapted for installation into a duct having an inner bore diameter of approximately 8 mm.

19. The pre-terminated optical fibre cable assembly as claimed claim 1, wherein the protective sleeve is fixed against longitudinal movement relative to the optical fibre, by fixing at least a first end of the protective sleeve to an underlying layer.

20. The pre-terminated optical fibre cable assembly as claimed in claim 19, wherein the protective sleeve is fixed against longitudinal movement relative to the optical fibre, by fixing both ends or along its full length.

21. The pre-terminated optical fibre cable assembly as claimed claim 1, wherein the protective sleeve is free moving over a section of the underlying optical fibre before it is installed.

22. The pre-terminated optical fibre cable assembly as claimed in claim 1, wherein the protective sleeve extends along the optical fibre for less than 10% of the length of the optical fibre.

23. The pre-terminated optical fibre cable assembly as claimed claim 1, wherein the protective sleeve comprises a plurality of layers.

24. The pre-terminated optical fibre cable assembly as claimed in claim 23, wherein the protective sleeve comprises an outer layer comprising at least a low-friction outer surface, a middle layer comprising a strengthening material, and an inner layer comprising a resilient material.

25. The pre-terminated optical fibre cable assembly as claimed in claim 24, wherein the outer layer of the protective sleeve comprises a polyethylene-based material comprising a friction reducing agent such that the outer layer exhibits low-friction properties.

26. The pre-terminated optical fibre cable assembly as claimed in claim 24, wherein the middle layer the protective sleeve comprises fibres such as aramid fibres.

27. A pre-terminated optical fibre cable assembly as claimed in claim 24, wherein the inner layer of the protective sleeve comprises a material that is resilient, heat resistant and chemical resistant.

28. The pre-terminated optical fibre cable assembly as claimed in claim 27, wherein the inner layer of the protective sleeve comprises a thermoplastic elastomer.

29. The pre-terminated optical fibre cable assembly as claimed in claim 28, wherein said thermoplastic elastomer is a copolyester.

30. A method of assembling a pre-terminated optical fibre cable assembly prior to installation through a duct, the method comprising the steps of: taking at least one optical fibre; fitting a protective sleeve onto a leading end of the optical fibre and extending the protective sleeve along a minor part of the length of the optical fibre; attaching a terminal connector to the leading end of the at least one optical fibre; and arranging the protective sleeve to extend from behind the connector along a minor part of the length of the optical fibre, wherein the protective sleeve extends towards a trailing end of the optical fibre.

31. The method as claimed in claim 30, further comprising the steps: fixing at least a part of the protective sleeve against longitudinal movement relative to the at least one optical fibre.

32. The method as claimed in claim 30, wherein said optical fibre is received embedded with one or more other optical fibres within a first layer of cured resin to form an optical fibre bundle, said protective sleeve extending over said optical fibre bundle.

33. The method as claimed in claim 32, wherein said optical fibre is received with said optical fibre bundle enclosed within an extruded outer sheath, and wherein the step of applying the protective sleeve includes removing of said outer sheath of the received cable assembly from at least part of the optical fibre bundle, before applying the protective sleeve over that part of the optical fibre bundle.

34. A method of installing a pre-terminated optical fibre cable assembly according to claim 1, the method comprising the steps: inserting the leading end of said pre-terminated optical fibre cable assembly into a duct, wherein the leading end includes the terminal connector and the protective sleeve; and transporting the leading end and a length of the pre-terminated optical fibre cable assembly through the duct.

35. The method as claimed in claim 34, further comprising: sealing the duct exit.

36. The method as claimed in claim 35, wherein sealing the duct exit comprises fitting a seal around the protruding section of the protective sleeve and fitting the seal to the duct exit.

37. The method as claimed in claim 36, wherein the seal includes a plug and a cap, wherein the method includes inserting the plug into the duct and closing the duct exit with the cap.

38. The method as claimed in claim 35, further comprising: installing an optical fibre clamp proximate the duct exit.

39. The method as claimed in claim 35, further comprising: clamping the protective sleeve proximate the duct exit, wherein clamping the protective sleeve is effective to prevent movement of the optical fibre relative to the duct.

40. The method as claimed in claim 52, further comprising: clamping the protective sleeve within or adjacent the connector body to prevent movement of the protective sleeve relative to the connector body.

41. The method as claimed claim 34, further comprising connecting one end of the pre-terminated cable assembly to supply equipment and another end of the pre-terminated construction to consumer equipment.

42. The method as claimed in claim 41, wherein said terminal connector comprises a ferrule connector and, wherein the method further comprises adding a connector body to the ferrule connector of the pre-terminated optical fibre cable assembly after installation in the duct, wherein the connector body facilitates the connecting step.

43. The method of installing a pre-terminated optical fibre cable assembly according to claim 34, wherein the step of transporting a length of the pre-terminated optical fibre cable assembly through the duct continues until a leading portion of the pre-terminated optical fibre cable assembly protrudes from the duct, protected by so protective sleeve.

44. The method as claimed in claim 43, wherein after the step of transporting a length of the pre-terminated optical fibre cable assembly through the duct a section of the protective sleeve remains within the duct.

45. The pre-terminated optical fibre cable assembly as claimed in claim 12, wherein the polymer of the surface of the protective sleeve is Polypropylene.

46. The pre-terminated optical fibre cable assembly as claimed in claim 24, wherein the outer layer of the protective sleeve comprises Polypropylene and a friction reducing material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Embodiments of the present invention are described below, by way of example only, with reference to the accompanying drawings, in which:

[0067] FIG. 1 is a schematic representation of a method of installing Fibre to the Home (FTTH), which includes installing a pre-terminated optical fibre construction according to an embodiment of the present invention;

[0068] FIG. 2 is a schematic representation of a blowing process, as an example of how to install a pre-terminated optical fibre construction according to an embodiment of the present invention between a home location and a transmission/supply location;

[0069] FIG. 3 is a schematic representation of when the leading end of a pre-terminated optical fibre cable assembly exits the duct according to an embodiment of the present invention, with different amounts of the cable assembly protruding from a duct at (a) and (b); There is 3a and 3b which need further explanation.

[0070] FIG. 4 is a schematic representation of a securing a pre-terminated optical fibre cable assembly according to an embodiment of the present invention to the duct after the leading end exits the duct; breakthrough; (where required, as it is not always required)

[0071] FIG. 5 is a schematic (This is more of a picture than a schematic) representation of a pre-terminated optical fibre cable assembly according to an embodiment of the present invention showing the pre-terminated leading end;

[0072] FIG. 6 is a schematic representation of a pre-terminated optical fibre construction according to an embodiment of the present invention showing the configuration of a protective sleeve applied to the pre-terminated optical fibre cable assembly;

[0073] FIG. 7 shows in more detail part of a pre-terminated optical fibre cable assembly, in three embodiments (a), (b) and (c);

[0074] FIGS. 8 (a) to (e) are schematic representations of the stages of assembly of the terminal connector as applied to the end of the pre-terminated optical fibre construction according to an embodiment of the present invention after the leading end exits the duct;

[0075] FIG. 9 shows an accessory for use in pulling installation of a pre-terminated cable assembly;

[0076] FIG. 10 illustrates schematically an optical fibre cable assembly pre-terminated and provided with protective sleeves at both ends; and

[0077] FIG. 11 shows in two steps (a) and (b) the installation of the cable assembly of FIG. 9; and

DESCRIPTION

[0078] FIGS. 1 and 2 show an example of a Fibre to the Home (FTTH) installation 100 of optical fibres, using a pre-terminated optical fibre cable assembly 10 according to an embodiment of the present invention. It will be understood that terms such as consumer and home are used by way of example only, and the products and techniques described herein may equally be applied in commercial and industrial installations.

[0079] In the illustrated example, the pre-terminated cable assembly 10 is provided wound on a reel 12 from which pre-terminated optical fibre or fibres are delivered from the consumer side/home side 14 of the installation 100 to the supply side, for example a telecommunications cabinet 16. Instead of a reel 12, the pre-terminated cable assembly 10 may be provided in other forms, for example in a coil, in a fibre pan etc.

[0080] Referring also to FIG. 2, in the illustrated example, the FTTH installation 100 is performed by passing it into a pre-installed duct 20. Other ducts 20 etc, lead from the same cabinet 16 to other premises, so that this installation method may be repeated many times in a neighbourhood.

[0081] FIG. 2 shows, by way of example, installation by blowing, from the consumer side of the installation to the supply side. A leading end 18 of the pre-terminated optical fibre cable assembly 10 is transported through a duct 20 at least partly by viscous drag created by compressed fluid, for example compressed air. A special blowing machine 22 has a blowing head 21 which is coupled to the leading end 23 of the duct 20. It will be appreciated that the installation process may also be conducted from the supply side, for example a telecommunication cabinet 16, to the consumer side, according to convenience.

[0082] Depending on the situation, including for example the length of connection required, blowing may be the most suitable method of installation. However, the present disclosure is not limited to blowing. An alternative installation process (illustrated later in FIG. 8) involves physically pulling the leading end 18 of the pre-terminated optical fibre cable assembly 10 through the duct 20 via the trailing end or the duct exit 20. For shorter installations, simply pushing the assembly through the duct may be practicable.

[0083] The leading end 18 of the pre-terminated optical fibre cable assembly 10, which includes a ferrule connector 24, leads the installation of the optical fibre or fibres 46 through the duct 20.

[0084] The leading end 18 passes through the duct 20 and is fed from the reel 12 until the ferrule connector 24 and a length of the optical fibre cable assembly 10 exits the duct 20 within the telecommunications cabinet (see FIGS. 1 and 2). A protective cap may be fitted over the ferrule connector 24 while the installation takes place. In an embodiment where pulling is used instead of blowing, an adapter can be applied to provide a pulling eye and to protect the ferrule connector 24 from damage during pulling. One example of such an adapter is described below and is illustrated in FIG. 8.

[0085] The action of the leading end 18 of the optical fibre cable assembly 10 exiting the far end of duct 20, following installation by blowing or pulling, is often referred to as breakthrough, as illustrated in FIGS. 3 and 4.

[0086] A fibre catcher (not illustrated) may be used to indicate when the leading end 18 of the optical fibre cable assembly 10 has reached its destination, that is, when the leading end 18 has exited the duct 20 and when a predetermined length of the optical fibre cable assembly 10 is within the cabinet 16. Alternatively, an installer may observe when the leading end 18 exits the duct 20, and communicate with the operator of the blowing machine 22 to cease blowing.

[0087] Referring now to FIG. 3, suppose that 1.5 metres is considered sufficient length of optical fibre to allow routing and connection within the telecommunications cabinet 16. Therefore, the length of optical fibre that exits the duct 20 may be in the region of 1.5 metres. Naturally, it is unusual that the length of optical fibre 10 protruding from the duct 20 will be exactly 1.5 metres, or exactly the length required for a particular connection point. The actual length may be slightly shorter or more likely slightly longer than the ideal, because of possible reaction-induced time delay in shutting off the blowing machine. For example, blowing may continue for slightly longer than when the fibre catcher indicates the fibres have exited the duct 20; even a short period of continued blowing may result in ripples along at least part of the length of the optical fibre cable assembly 10. When blowing stops, this ripple effect may result in a further length of optical fibre exiting the duct 20 (see FIG. 3b). It will be appreciated, especially in the case of a long blowing route, the excess length of optical fibre exiting the duct cannot be pulled back via the trailing end because this could lead to damage of the optical fibre within the duct 20. The ability to push excess back into the duct from the leading end may also be limited.

[0088] In the illustrated example (see FIGS. 2, 3 and 4) a protective sleeve 26 is provided along part of the length of the pre-terminated optical fibre cable assembly 10 such that a section of the protective sleeve 26 remains within the duct 20 after the leading end 18 exits the duct 20.

[0089] The protective sleeve 26 extends from a position behind the connector 24 along a minor length of the optical fibre cable assembly 10. The length of the protective sleeve 26 is such that a trailing part 28 of the protective sleeve 26 remains within the duct 20 after breakthrough, and a leading part 30 of the protective sleeve 26 covers the optical fibres where they protrude from the duct 20.

[0090] Referring to FIGS. 3 (a) and (b), this arrangement provides a substantial tolerance for variations in the length of the optical fibres that protrudes from the duct 20. No tailoring of a protective sleeve is required, after the leading end 18 exits the duct 20. The excess length of protective sleeve simply resides within the duct.

[0091] After the leading end 18 exits the duct 20, installation at the telecommunications cabinet 16 is completed by plugging the open end of the duct 20 with a suitable accessory.

[0092] In the illustrated example, the duct 20 is plugged with a hollow connector 32 that has an outer diameter 34 that is configured to be a push-fit into the duct 20 and has a hollow or groove into which the protective sleeve 26 containing the optical fibres is received. A flange 36 is provided as a stop/seal on the outside of the connector 32 should this be preferred by the operator. The flange 36 is operable to cap the exit of the duct 20.

[0093] In the illustrated example, with reference also to FIG. 4 an exposed extension member 38 of the hollow connector 32 extends beyond the flange 36 and envelops part of the protective sleeve 26. A capping sleeve 40 may be added to the exposed extension member 38. The capping sleeve 40 is operable to locally compress the protective sleeve 26 against the fibre cable assembly 10 to prevent fibre movement after installation of the optical fibre construction.

[0094] FIG. 5 illustrates in more detail one example of the connector 24 that may be used at the leading end of the pre-terminated optical fibre cable assembly 10. It will be understood that the ferrule connector 24 is of a size suitable for installation through the duct 20, and may not form a complete connector assembly until other components are added. In the illustrated example, the ferrule connector 24 includes a ferrule body 44 which facilitates attaching a connector body after the leading end 18 exits the duct 20, as described below with reference to FIG. 7. It will be understood that, while the cable may carry more than one optical fibre, for example 2 or 4 optical fibres, in the majority of installations, only one of these fibres carries live signals, and only that one is provided with a ferrule connector 24. The unused fibres are used, when necessary, as backup.

[0095] In one specific example comprising two ferrule connectors (not illustrated) connected to two individual optical fibres within the cable assembly, each ferrule body 44 is D-shaped in cross-section. The flat portions of the D-shaped bodies are abutted such that the combined dimension of the abutted bodies is small enough so both ferrule bodies can pass together through the duct. In practice, the combined dimension of the abutted ferrule bodies need not be any greater than the outer diameter of the protective sleeve 26.

[0096] The protective sleeve 26, as described above with reference to FIGS. 1 to 4, may extend along a minor part of the pre-terminated optical fibre cable assembly 10 and extends from behind the ferrule connector 24. The cable assembly 10 may be tens or even hundreds of metres in length, while the portion protected by the protective sleeve 26 may be a few metres or less. In this way, construction of the protective sleeve 26 can be optimised for protecting the optical fibres where they are vulnerable, outside the duct 20. Such a protective sleeve, applied to the whole length of the cable assembly, might otherwise degrade the installation performance, completely preventing installation by blowing, for example. Provision of such a protective sleeve along the whole length of the cable assembly may alternatively, or in addition, add unduly to the cost of the cable assembly, and or the weight and/or size. Particularly when many ducts are to be run in parallel, to serve different consumers within a street, building etc, any increase in the size of the cable assembly, and consequently the size of the individual duct required to carry it, can have a very significant effect on the size of the total space taken up by ducts, and the size of the cabinets needed for termination.

[0097] FIG. 6 presents an example of the construction of the pre-terminated optical fibre cable assembly 10, as viewed in a portion comprising the protective sleeve 26. By way of illustration only, FIG. 6 shows, in cross-section, an optical fibre cable assembly 10, which includes four primary coated optical fibres 46. A fibre bundle 48, in this example, comprises the optical fibres 46 embedded in a UV-cured resin 50. Each optical fibre 46 may be, for example, 200 m to 250 m in diameter. The optical fibre bundle 48 has an outside diameter which may, for example, be less than 1 mm, typically in the region of 0.9 mm. The diameter of the bundle will of course increase and decrease to some extent, according to the number of fibres contained within it. Features within the bundle are not shown to scale. The thickness of resin over the optical fibres may be, for example 50 m, at the minimum.

[0098] In the illustrated example, the protective sleeve 26 includes a layered construction which is applied by sliding directly over the fibre bundle 48. It will be appreciated that the positions and thicknesses of the layers in FIG. 6 are not to scale, but purely schematic. The internal diameter of the protective sleeve 26 may in practice be greater than the outer diameter of the fibre bundle 48, such that the protective sleeve 26 is easily applied and slides over the fibres freely. In an example, the inner diameter of the protective sleeve 26 is greater than 1 mm, for example in the region of 1.1 mm; thereby providing 0.1 mm or more clearance around the fibre bundle 48. In the illustrated example, the protective sleeve 26 has a construction, providing an outer diameter in the region of 2.1 mm and an inner bore in the region of 1.1 mm to freely receive the fibre bundle 48.

[0099] The construction of the protective sleeve 26, as illustrated in FIG. 6, has three layers. An inner layer 52 may be, for example, approximately 0.3 mm thick (300 microns) and provides flexibility to the protective sleeve 26. The inner layer 52, in this example, is made of a compound that is resilient, heat resistant and chemical resistant, for example Hytrel. Hytrel is a thermoplastic elastomer, specifically a copolyester material, which combines the flexibility of rubber with the strength and processability of thermoplastics, thus ensuring flexibility of the section of the fibre bundle 48 to which the protective sleeve 26 is applied.

[0100] The middle layer 54 of the protective sleeve 26 is a strengthening layer. In the illustrated example the middle layer 54 comprises aramid fibres, commonly known by the tradename Kevlar.

[0101] The outer layer 56 of the protective sleeve 26 provides a low friction outer surface, as well as covering the layers below so that the favourable installation properties of the cable assembly 10 as a whole are not compromised. The low friction outer surface may be provided by a coating of a low-friction material or by blending a material having low friction properties with a sheath material. The sheath material may be, for example, high density polyethylene (HDPE), medium density polyethylene (MDPE), nylon or polypropylene. The use of a low friction material assists in the transportation of the pre-terminated optical fibre cable assembly 10 through the duct. Particularly in a cable assembly adapted for installation by blowing, frictional properties, as well as other properties of the cable assembly are very important. Even though the protective sleeve 26 may cover only a minor portion of the overall length, it is important that the protective sleeve 26 is designed not to degrade the installation properties unduly. This is, of course, a requirement that does not apply to conventional protective sleeves, of the type that might be added to protect the protruding end of the cable assembly, after it has been installed.

[0102] The protective sleeve 26 material may also have flame retardant properties, and/or example low smoke zero halogen (LSOH or LSZH). It is desirable that the protective sleeve 26 exhibits low fire hazard properties outside the duct 20 because it will be exposed once installed. Parts of the cable assembly 10 which are contained within the duct 20, may be protected against fire by the duct itself. For example, the protective sleeve 26 may comprise a polyethylene based material, comprising a friction reducing agent such that the outer layer exhibits low-friction properties. An example of a suitable material for the outer layer 56 may be a mixture of high density polyethylene (e.g. Borstar) and a friction reducing agent. The friction reducing agent, which may also be called a slip agent, might be, for example, a silicon-based material including a polyether modified poly (dimethylsiloxane) material such as a polyether modified hydroxy functional poly-(dimethylsiloxane) material. As an alternative to, or in addition to, the friction reducing materials described in the above embodiments, erucamide and/or oleamide materials may be used as slip agents.

[0103] It will be appreciated that, as an alternative to the layered construction described above, the protective sleeve 26 may be constructed from a single layer, or multiple layers of composite material, which provides the structural, chemical and low-friction properties required to protect the underlying fibre bundle 48 and the optical fibres 46 during installation and after installation.

[0104] In one embodiment, the fibre bundle 48 may be covered by an outer sheath (not illustrated in FIGS. 1-6), which extends substantially the full length of the optical fibre bundle 48. This embodiment may for example be based on a cable assembly of the type disclosed in WO2004015475, mentioned above, in which the outer sheath is extruded onto the optical fibre bundle during manufacture. The outer sheath may be made for example of HDPE, with or without a friction-reducing additive. The outer sheath protects the bundle and facilitates sliding of the bundle through the duct 20, much more easily than if the acrylate material of the coating of the bundle 48 were in direct contact with the interior of the duct. The outer sheath is stripped from the ends of the cable assembly, to gain access to the bundle and the optical fibres, for termination, splicing etc. It is a matter of choice, whether this outer sheath remains in place underneath the protective sleeve 26, or is omitted, in those parts of the cable assembly where the protective sleeve 26 covers the optical fibre bundle 48. These different options are illustrated in more detail, in FIG. 7.

[0105] Referring generally to FIG. 7, a pre-terminated optical fibre cable assembly 10, can be assembled by sliding the protective sleeve 26 over an end section of a longer, pre-manufactured optical fibre cable assembly. FIG. 7(a) illustrates an example where the pre-manufactured optical fibre cable assembly has an outer sheath 58 which remains in place under the protective sleeve 26. It will be appreciated that the inner diameter ID26 of the protective sleeve 26 and the outer diameter OD58 of the outer sheath are dimensioned such that the protective sleeve 26 slides freely over the outer sheath.

[0106] In another embodiment, illustrated in the detail of FIG. 7(b), a section of the outer sheath 58 is removed and the protective sleeve 26 is added to the resulting exposed section of the fibre bundle 48. In this example, the inner diameter ID26 of the protective sleeve 26 maybe smaller than the outer diameter OD58 of the outer sheath, being dimensioned such that the protective sleeve 26 slides freely over the coated fibre bundle 48 only.

[0107] In a further alternative embodiment, illustrated in FIG. 7(c) the protective sleeve 26 overlaps a short section of the outer sheath 58. For example, the protective sleeve 26 may extend a metre or two behind the leading end 18 of the optical fibre cable assembly 10, while the outer sheath 58 extends to a point that overlaps with the protective sleeve 26 by a centimetre or a few centimetres. The protective sleeve 26 may have dimensions the same as in FIG. 8(a), in this case, or maybe slightly smaller, and stretch to fit over the end of the remaining outer sheath 58.

[0108] In the manufacture of the optical fibre cable assembly 10, the protective sleeve 26 in some embodiments is bonded to the underlying layer at some point. In other embodiments, bonding may be unnecessary. As illustrated in FIG. 11(a), this bonding can be applied at the trailing end of the protective sleeve 26, such that movement of the protective sleeve 26, relative to the optical fibres 46, is prevented during installation or the protective sleeve 26. If bonded, suitable bonding locations may be those indicated schematically with reference 59. While this example illustrates bonded locations 59 at the trailing end of the protective sleeve 26, bonding locations may alternatively or additionally be provided at the leading end 18 of the protective sleeve 26, or along the length of the protective sleeve 26, or at intermittent points along the length of the protective sleeve 26. The protective sleeve 26 may be bonded, for example with suitable adhesive (e.g. a common cyanoacrylate adhesive, also known as Superglue), such that the protective sleeve 26 remains stationary relative to the fibres 46, the fibre bundle 48 or outer sheath 58 during installation of the pre-terminated optical fibre cable assembly 10. Depending on the embodiment, the underlying layer to which the protective sleeve 26 is bonded may be an outer sheath 58, or a coating 50 of the fibre bundle 48. In principle, the portion of the cable assembly 10 over which the protective sleeve 26 extends might contain only the primary coated optical fibres 46.

[0109] In the example of FIG. 7(b), potential bonding locations 59 are indicated, but in one particular embodiment, bonding is unnecessary. Recalling that protective sleeve 26 may have an inner diameter less than the outer diameter of outer sheath 58, the end of outer sheath 58 forms a natural stop, beyond which the protective sleeve cannot slide. Similarly, at the leading end of the cable assembly 10, ferrule connector 24 provides a stop, beyond which the protective sleeve 26 cannot slide. As described further below, it is expected that leading end of protective sleeve 26 will be clamped to the underlying fibre bundle. An advantage of not bonding the protective sleeve 26 to the fibre bundle 48 is that the protective sleeve 26 will be free to expand or contract due to heat and cold, without transmitting any forces to the fibre bundle 48.

[0110] As an alternative to adhesive, heat-shrinking or other fixing methods can be considered, provided they do not damage the underlying structure, of course, or result in a bulky profile. As mentioned already, in a variation of the example of FIG. 7(c), the inner diameter of the protective sleeve 26 may be made smaller than the outer diameter of outer sheath 58, so that the end of the protective sleeve 26 has to stretch over the end of the outer sheath 58, becoming fixed against longitudinal movement by friction.

[0111] An inner bore of the intended duct 20 is illustrated in broken lines, with inner diameter ID20. It will be appreciated that the embodiment of FIG. 7(a) is likely to have a larger outer diameter of the protective sleeve 26, and therefore require a larger duct for installation. As mentioned already, space is normally precious, and it may be an advantage of the embodiment of FIG. 7(b) that the protective sleeve 26 can have a smaller outer diameter, and therefore travel within a smaller duct. Embodiments of this latter type can be designed to travel through the conventional micro-duct, for example having an internal bore of only 3.5 mm.

[0112] Another step in the assembly of the pre-terminated optical fibre cable assembly 10 is adding a connector 24, for example a ferrule connector, to the leading end 18 of one or more of the optical fibres 46 within cable assembly 10. If this step is performed after sliding on protective sleeve 26, the ferrule connector 24 need not pass through the protective sleeve 26, and a more compact construction is enabled. The ferrule connector 24 can be added before or after the protective sleeve 26 is bonded to the optical fibre bundle, terminating at a location closely behind the ferrule connector 24. The precise location can be determined by reference to the subsequent steps for adding a connector body to the ferrule connector 24. The steps will be illustrated below, with reference to FIG. 8. To allow precise positioning, it is proposed to bond the trailing end of the sleeve only after fitting the ferrule connector 24.

[0113] The optical fibre cable assembly 10 is then ready for installing by blowing, pushing or pulling as described above with reference to FIGS. 1 to 4.

[0114] Referring to FIG. 8, after the leading end 18 of the optical fibre cable assembly 10 emerges from the duct 20, a connector body is fitted over the ferrule connector 24. In the illustrated example, the connector body includes a boot 60, a rear housing 62 and a front housing 64. As illustrated in FIG. 8, steps (a) to (e) the boot 60, the rear housing 62 and the front housing 64 are fitted over the ferrule connector 24 in a particular sequence, to complete construction of the optical fibre cable assembly 10 prior to connecting within the telecommunications cabinet 16.

[0115] Referring to FIG. 8(a), the boot 60 is slid over the ferrule 24 and part of the protective sleeve 26 in the direction of arrow 66. Next, in FIG. 8(b), the rear housing 62 is applied by inserting the ferrule 24 and a section of the protective sleeve 26 into a recess in the rear housing 62 in the direction of arrow 68.

[0116] Referring to FIG. 8(c), assembly of the rear housing 62 is completed by pushing the boot 60 in the direction of arrow 70, over the rear section of the rear housing 62. By this action, the rear housing 62 of the connector clamps the protective sleeve 26 and the rear section of the ferrule 24 against the underlying layers of the optical fibre cable assembly 10 and grips them securely within the rear housing 62.

[0117] Referring to FIG. 8(d), assembly of the connector body 72 is completed by applying the front housing 64 to the front end of the rear housing 62, in the direction of arrow 74. The rear housing 62 comprises resilient locking pegs 76 (see (b) and (c)). The locking pegs 76 locate in holes 78 provided on the walls of the front housing 64 such that when the locking pegs 76 engage with the holes 78 the front housing 64 is locked in place. The finished connector body 72 is shown in FIG. 8(e) end of the optical fibre is thus ready for connecting to a receiving port 80 inside the telecommunications cabinet 16 (FIG. 1). The skilled reader will recognise that connector 72 in this example is of a standard LC type. Other types of connector can be provided. It is a matter of detailed implementation, whether the rear housing 62 is identical to known designs, or is modified specifically to accommodate the leading end of protective sleeve 26.

[0118] If desired, the process illustrated in FIG. 8 can be repeated at the opposite end of the optical fibre, to create a double pre-terminated cable assembly (described below with reference to FIGS. 10 and 11). In current practice, an SC connector is commonly used to terminate the optical fibre at the consumer premises. In embodiments of the present disclosure, the more compact LC type connector is used at both ends. The ferrule connector 24 of the LC connector can be smaller, and compatible with the micro-ducts used for blowing. Referring again to the specific example where each ferrule body 44 is D-shaped in cross-section, this D-shaped profile can be seen in the rear opening of boot 60, in the example of FIG. 8. Ferrule bodies having the D-shaped profile can of course be used in installations where only a single fibre is terminated, as shown here, as well as installations where a pair of fibres are terminated and the ferrule bodies lie side-by-side during installation in a duct.

[0119] Installing a protective sleeve 26 prior to installing the pre-terminated optical fibre cable assembly 10 through a duct 20, advantageously removes the post-installation step of installing a protective outer jacket, for example a braided or woven sleeve, to the optical fibre cable assembly 10 in the field, for example at a telecommunication cabinet. It will be appreciated that installing braiding can be time consuming and it can fray if adjustment is required. This can expose the fibre bundle 48 and could lead to damage of the optical fibres 46. If the braiding becomes disconnected or broken, the connector body may become disconnected. In addition, the interior of the cabinets can look untidy and unfinished. Dozens or even hundreds of connections may be made in the same cabinet, meaning that the fibre and sleeve can be subjected to repeated disturbance over their lifetime.

[0120] As mentioned, the cable assembly of the type disclosed herein can be installed by blowing, or by pushing, pulling, or by a combination of these processes. For pulling, it may be noted that ducts can be purchased which are pre-loaded with a pulling line.

[0121] FIG. 9 illustrates a pulling accessory 82 that can be used with a pulling line, to install an optical fibre and/or optical fibre cable that has been pre-terminated with a ferrule connector 24. The coated fibre bundle 48 is shown, which is also fitted with a protective sleeve 26 (shown in dotted lines). Two of the accessories are illustrated, one fitted to the end of the optical fibre, and one spare. As can be seen, the pulling accessory 82 has a recess 84 tailored to fit over the pre-terminated end of the optical fibres, capturing the ferrule body 24. At a rounded front end of the pulling accessory 82, a pulling eye 86 is provided, for attaching the pulling line (not shown).

[0122] As is known by the skilled person, the distance that a length of optical fibre cable that can be installed by pulling or pushing may be significantly less than the distance that can be obtained by blowing, but it may be adequate, for example for short drops within a building, or from street to building.

[0123] FIG. 10 illustrates another example of a pre-terminated optical fibre cable assembly 90 constructed in accordance with the principles of the present disclosure. This example, is a length of optical fibre cable 92, which is pre-terminated at both ends with ferrule connectors 24a and 24b, and both ends are provided with protective sleeves 26a and 26b. The cable 92, as delivered, is coiled in a pan 96 or wound on a reel, in the conventional manner. The types of connectors at the different ends can be the same or different. The lengths of protective sleeve 26 can be the same at both ends, or different, as shown. For particular applications, the structure of the protective sleeve 26a may even be different to that of protective sleeve 26b. In particular, it is envisaged that one of the ends of the cable assembly 90 might be installed by blowing, over a large distance, say, while the other end is installed over a shorter distance, for example by blowing, pushing or pulling. One of the ends may terminate at a communications cabinet, while the other end terminates within a consumer premises, such as a house or office.

[0124] FIG. 11 illustrates an example of such an installation, using the double-ended pre-terminated cable assembly 90. A first installation step is illustrated in FIG. 11(a) and a second installation step is illustrated in FIG. 11(b). The first installation step corresponds, for example, exactly to the blowing installation process described above with reference to FIGS. 1 and 2. From an access point 102 on the exterior of a building 114, a first end of the cable assembly 90 is installed by blowing to a cabinet 116. The installation distance may be hundreds of metres or more. At the end of this first installation step, the second end of the cable assembly, and a coil of excess cable, remain at the access point.

[0125] In the second installation step illustrated in FIG. 11(b), the second end of the cable assembly 90 is installed into a local drop duct, to reach a particular apartment or room within the building 114. As illustrated, this may be a consumer's connection point 104 on an upper floor of the building. This installation step, which may comprise only a few metres of cable, may be performed by manual pushing, pulling or blowing if necessary. Within the consumer premises, the connector body can be added to the ferrule connector, while the pre-fitted protective sleeve protects the protruding length of the cable. Excess cable can be stored at a suitable point on the installation, for example in the home/office at connection point 104, or in a termination housing 102 at the side of the building (as shown in FIG. 11), or at some point in between. When the cable assembly 10 or 90 is lightweight and compact to begin with, storing the excess length is not such a problem as it is in the case of the bulky drop cable described in the disclosure of WO2014/015902A1A, mentioned in the introduction.

[0126] Using pre-fitted protective sleeves, in the manner described, improves the installation process, by reducing post installation steps and time. As such, production costs and assembly costs may be reduced compared with subsequently applying a protective sleeve, in particular a braided or woven sleeve. The existing solution, a protective sleeve added after installation, is typically of larger diameter, than the pre-installed protective sleeve 26 described above. This can be because of the nature of the manufacturing process to produce a braided protective sleeve braid, which comprises multiple overlapping yarns. This could also be because the braid needs to be large enough to pass over the ferrule connector 24. Therefore, preinstalling a protective sleeve 26 as described above saves space and therefore facilitates more installations within one cabinet.

[0127] Additionally, following the principles of the present disclosure, the delicate steps of fibre termination and assembly of the entire pre-terminated cable assembly with protective sleeves can be performed in a controlled factory environment, rather than in the field. As explained already above, and as illustrated in FIG. 3, the length of the pre-fitted protective sleeve 26 does not need to be precisely tailored to a particular installation. Needs only to be sufficient that to protects whatever length of optical fibre will be protruding from the duct. As described, these measures can be applied to only one end of the cable assembly, or to both ends. These measures can be applied especially to a compact and lightweight cable, of the type designed for installation by blowing, although the method of installation is by no means limited to blowing. The present disclosure encompasses kits of parts for use in producing pre-terminated optical fibre cable assemblies of the type described, as well as the method of manufacturing such assemblies, and the stocking and distribution of such assemblies for installation, together with accessories involved in the installation. The present disclosure encompasses methods of installation, as described, including the cable assemblies.

[0128] Whilst specific embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the present invention.