Have you ever wondered what makes Fiber optic cables better than traditional copper wires? If so, then do remember that Fiber cables are made with high-grade glass cores and environmental protective sheaths, which can endure everything from residential network connections to underwater links. In this article, we’ll discuss in detail the construction of Fiber optic cables and also see the challenges you might face. So, keep reading to learn why these cables are the communication backbone of the world.
Figure no 1 Fiber Optic cable construction
1) Fiber Optic Components and materials
Fiber optic cables may appear thin and fragile. However, they are composed of many components, each constructed from advanced materials to guarantee the quick and reliable transmission of data. So, let’s break it down!
i) Core: The heart of Fiber cable
The core is the primary part of a Fiber optic cable. It’s responsible for carrying light signals (data) and transmitting them at near-light speed. Moreover, the quality of the core dictates the distance and speed data can be traversed with minimal loss. There are two main types of cores employed in Fiber optics:
a) Glass (Silica Core): These glass Fibers are composed of high-purity silica glass (SiO₂), the type used in most telecommunications and internet connections. It enables data transmission over hundreds of kilometres with minimal signal loss.
b) Plastic Optical (POF): This type of Fiber is made from lower-cost plastic and does lose signal faster than glass Fibers. However, it’s good for short-distance applications, such as home entertainment systems or vehicles.
Moreover, to better control the core’s light propagation, specialized materials are added through a process referred to as doping. For instance;
- Germanium (GeO₂): A compound that helps increase the refractive index and hold light in the core.
- Phosphorus (P₂O₅): It further enhances glass features to increase the durability and performance of the Fiber.
Figure no 2 Fiber Optic key constituents
ii) Cladding Layer
Every core of an optical fiber is surrounded by a cladding layer, which is very important because it prevents the loss of light from the core. It functions due to a phenomenon known as total internal reflection, which means that light in the Fiber core does not escape but reflects off the sides of the core and continues to travel forward.
Unlike the core, cladding is made of a different type of silica glass that has a lower refractive index. This difference in the refractive index ensures that light signals do not escape from the Fiber, thus enabling long-distance propagation without any interruptions.
iii) Buffer Coating
The buffer coating is the outer protective layer of the Fiber. In the absence of this layer, the Fiber would be extremely delicate and would not withstand an average amount of stress. The buffer coating guards against moisture, chemicals, and physical stress. Some common materials used for buffer coating are:
- Acrylate: Coating that is more flexible and light; thus, it is useful in most applications.
- Polyimide: Used in aerospace and other industrial high-temperature applications due to its heat-resistant properties.
2) Strengthening and Protective Layers in Optic Cable
Purpose | Materials | Key Benefits | |
| Strength Members | Prevents stretching and breaking | Kevlar®, Steel Rods, glass | Increases durability and flexibility |
| Outer Jacket | Shields from fire, UV, and chemicals | PVC, LSZH, Polyurethane | Enhances safety and longevity |
| Waterproofing | Blocks moisture damage | Gel-Filled, Dry-Core | Extends lifespan in wet conditions |
| Armouring | Protects from impact and rodents | Steel Tape, Aluminum Shielding | Ensures durability in harsh environments |
3) Manufacturing Process of Fiber Optic Cables
Manufacturing fiber optic cable is like constructing the ideal superhighway for light signals. These below-mentioned steps are required to be followed with a high degree of accuracy so fast communication can be achieved with clarity. Let’s go ahead with the specific procedures.
Step 1: Making the Preform – The Blueprint
The Fiber optic cable construction starts with a pre-form formation, which is the super pure rod of thick glass that will be stretched into a Fiber. The rod uses ultra-pure material and light, so projecting light will not get scattered.
Step 2: Drawing the – Stretching it Thin
Now, you can place the pre-form in a furnace heated to an excess of 2000 degrees Celsius and convert the pre-form to its desired outcome. As molten glass is being poured, it is carefully stretched until it is one-hundred-and-twenty-five microns (µm), or human hair thick!
For protection and flexibility, a liquid coating is applied immediately after stretching. Further, UV light is used to instantly harden the coating to ensure that the Fiber is tough and free from any cracks.
Figure no 3 Fiber optic manufacturing process
Step 3: Cable Assembly – Adding Protection
Adding extra layers increases the survival rate and durability of the Fiber, allowing it to withstand real-world conditions. This can be done through purposeful layering. For instance,
- First, the Fibers are placed inside buffer tubes for protection against moisture and bending.
- Next, Kevlar® or steel rods are used as strength members to prevent stretching and snapping.
- Afterward, an outer jacket made of PVC, LSZH, or polyurethane is used. This shields the structure from water, fire, and other damage.
Lastly, for multi-core cables, several protective layers are used alongside a multi-fibre bundle, allowing additional customization.
Step 4: Quality Control Procedures: The Final Steps of Perfection
Prior to setting these cables up for use, they undergo an exhaustive series of tests to evaluate performance in a variety of conditions. These are the specific tests performed:
? Attenuation Test: This test assesses the degree of attenuation that occurs to the light signal as it travels along the Fiber. The target remains a signal loss of 0.2 dB/km as a maximum value, which is extremely low, thereby maximizing data transmission clarity and speed.
? Tensile Strength Test: The Fiber optic cable is stressed through tension and pulled at a high force to test its breaking point. This assures that the cable can withstand stretching during installation without fracturing.
Figure no 4 Fiber Optic Quality tests
? Crush Resistance Test: Static loads are applied to the cable to mimic realistic scenarios, such as its burial underground or being driven over by vehicles. The Fiber must remain intact and continue the uninterrupted transmission of signals.
? Temperature and Environmental Stress Test: The cable is subjected to hot and cold temperatures, alongside humid conditions, to assess expansion and contraction over time. This guarantees functionality regardless of the intended installation environment, such as deserts, mountains, or deep underwater.
After the Fiber optic cables complete their testing, they are good to go for shipping and installation, which enables reliable and fast internet, phone calls, and data transmission for millions across the globe!
4) Construction Variations for Different Applications
These adaptions of Fiber optic cable differ due to the location where they are intended to be used. Let us explore the variations.
- Indoor vs. Outdoor Optic Cables
- Indoor: Buildings necessitate the usage of indoor cables that are both safe and flexible. Hence, for enhanced fire resistance, the outer jacket is typically constructed of PVC or LSZH (Low Smoke Zero Halogen). Moreover, their lightweight nature makes them simple to place within confined areas.
- Outdoor: Outdoor cables face much harsher conditions, so they need extra protection. For instance, lightweight materials that are UV and waterproof-resistant are used in the wearing of the jacket. Moreover, Fibrous materials inside some cables that act as gel or water blockage aid in preventing moisture from corroding them.
Figure no 5 Outdoor Armoured Fiber Cables
- Aerial and Underground Cables
Exposed cables that are hung between poles require additional support in the form of strong messenger wires to hold them up. The wires guard against bending and snapping during powerful breezes.
Steel or aluminium underground armouring is ideal for defending cables from dirt, rocks, and pressure. There are also thicker waterproof layers that block moisture, which enables some to forgo the materials.
- High-Density Ribbon Cables
For a data center type of location that needs thousands of s in a small area, ribbon cables bundle numerous s in the form of a ribbon. They enable quick and simple splicing, which helps in faster installation. They may be small in size, but the amount of data that can be transmitted simultaneously is massive!
5) Challenges in Optic Cable Construction
Constructing the Fiber optic cables may seem easy, however, they come with difficult challenges. Here are some of the greatest:
? Achieving a high level of purity within the core: To ensure perfect signal transmission, Fibers must be 99.9999% pure glass. Any impurities can severely affect the quality of the signal, leading to slower internet speeds and phone call connectivity.
? Maintaining Flexibility and Rigidity: A combination of these factors enables effective functioning. Cables must retain effortless flexibility while bending and unique strength while enduring stretching, crushing, and twisting.
? Extreme Environments and Temperature Control: Typically located on Fiber optic cables, these can be found in many places, ranging from freezing mountains to high-altitude deserts. They allow for expansion and contraction without cracking and damage prevention from exposed water, snow, and heat. Further, exposing them to -40C and 80C allows them to stay flexible, signifying greater strength to withstand extreme temperatures.
? The High Cost and Complexity of Manufacturing: Building cables of optical Fiber requires advanced, precise, and costly machinery. Manufacturing these Fibers is considered an entire process; a single error can render all Fibers useless!
6) Conclusion
The construction of optical Fiber cables focuses on speed along with strength. The entire structure, starting from the glass core and ending with the protective shell, is designed to relay communication to the user swiftly and clearly. As technology progresses, so will Fiber optics. So, if you are looking to upgrade your network, then look no further than Dekam Fiber. We specialise in producing customized Fiber solutions. So, contact us today!
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