The present disclosure relates to the field of optical fiber, in particular, relates to slitted binder for high fiber count optical fiber cables. The present application is based on, and claims priority from an Indian Application Number 202011032795 filed on 30th July 2020, the disclosure of which is incorporated herein.

BACKGROUND
With the evolution of 5G and increase of data consumption in the recent years, application of data centres and telecoms have increased drastically. In addition, large scale data centers and telecom sectors require ultra-high fiber density cables that offers high data rate with low latency. The high fiber density cables include a large number of optical fibers inside cable. The optical fibers may be in the form of optical fiber ribbons or loose fibers. Traditionally, the structure of the optical fiber cables includes one or more buffer tubes, sheath surrounding the one or more buffer tubes, and optical fibers placed inside the buffer tubes. The buffer tube sheath protects the optical fibers from physical damage. The one or more buffer tubes occupy a lot of space inside the core of the optical fiber cable. Conventionally, poor packing efficiency of the optical fiber ribbons leads to the increase of cable diameter in the high fiber count cables. In addition, conventional high fiber count cables are inefficient at junction points and manhole installation. In case of the optical fiber ribbons tightly bound by winding a binder helically, the optical fiber ribbons of the conventional high fiber count cables collapse when load or force is experienced at centre of the optical fiber ribbons. European patent publication numbers EP3422063 and EP3168665 disclose two binders joined at intersections using heat-sealing and fusion methods to bind the ribbon bundle.
In light of the above stated discussion, there is a need for an efficient optical fiber solution for high fiber count cables that overcomes the above stated disadvantages.

OBJECT OF THE DISCLOSURE
A primary object of the present disclosure is to provide a slitted binder for binding at least two optical fibers or optical fiber ribbons and to increase fiber density in optical fiber cables.
Another object of the present disclosure is to provide a method of binding at least two optical fibers or optical fiber ribbons using slitted binder.

SUMMARY
In an aspect, the present disclosure provides a slitted binder. The slitted binder is utilized to produce high fiber counts in optical fiber cables. In addition, the slitted binder facilitates to increase fiber density in optical fiber cables by loosely binding a plurality of optical fibers or a plurality of optical fiber ribbons such as intermittently bonded ribbon, bendable ribbon etc. The slitted binder is used to loosely bind a bunch/bundle of a plurality of optical fibers, the plurality of optical fiber ribbons, and/or an optical fiber ribbon stack. The slitted binder includes one or more colours to differentiate between the bundle of the plurality of optical fiber ribbons or the plurality of optical fibers. The slitted binder is manufactured using different types of material that is chosen based on type of application or usage. The slitted binder includes a plurality of slits in longitudinal direction along a length of the slitted binder. The plurality of slits 102 may have length L in range of about 20 millimeter to 50 millimeter. The one or more types of the slitted binder may include water swellable element, and/or one or more repellents. In addition, the one or more repellents include moth, termites, and rodent. The type of material may include natural material, synthetic material, metals and minerals.
These and other aspects herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the invention herein without departing from the spirit thereof.

STATEMENT OF THE DISCLOSURE
The present disclosure provides a slitted binder. The slitted binder is utilized to produce high fiber counts in optical fiber cables. In addition, the slitted binder facilitates to increase fiber density in optical fiber cables. The slitted binder is used to loosely bind a bunch of a plurality of optical fibers, a plurality of optical fiber ribbons, and/or an optical fiber ribbon stack. The slitted binder includes one or more colours to differentiate between the bundle of the plurality of optical fiber ribbons or the plurality of optical fibers. The slitted binder is manufactured using types of material that is chosen based on type of application or usage. The slitted binder includes a plurality of slits along the length of the slitted binder to loosely bind the bunch of the plurality of optical fibers, the plurality of optical fiber ribbons, and/or the optical fiber ribbon stack.

BRIEF DESCRIPTION OF FIGURES
Having thus described the disclosure in general terms, reference will now be made to the accompanying figures, wherein:
FIG. 1 illustrates a general overview of a slitted binder.
FIG 2 illustrates an example of the slitted binder with a cylindrical shaped optical fiber ribbon stack.
FIG. 3 is a flow chart illustrating a method for binding a bundle using the slitted binder.
It should be noted that the accompanying figures are intended to present illustrations of few examples of the present disclosure. These figures are not intended to limit the scope of the present disclosure. It should also be noted that accompanying figures are not necessarily drawn to scale.

DETAILED DESCRIPTION
In the following detailed description of the invention, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be obvious to a person skilled in the art that the invention may be practiced with or without these specific details. In other instances, well known methods, procedures and components have not been described in details so as not to unnecessarily obscure aspects of the invention.
Furthermore, it will be clear that the invention is not limited to these alternatives only. Numerous modifications, changes, variations, substitutions and equivalents will be apparent to those skilled in the art, without parting from the scope of the invention.
The accompanying drawings are used to help easily understand various technical features and it should be understood that the alternatives presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
FIG. 1 illustrates a general overview of a slitted binder 100. In general, a slit is a long, narrow cut or opening. The slitted binder 100 is utilized to produce high fiber counts in optical fiber cables. The slitted binder 100 facilitates to increase fiber density in optical fiber cables. The slitted binder 100 is used to loosely bind a bunch of a plurality of optical fibers, a plurality of optical fiber ribbons, or an optical fiber ribbon stack, therefore enables optical fiber bundle to change its shape, so that ribbon bunch/fibers bunch can adjust itself in any available space in the cable core. The optical fiber ribbon may be an intermittently bonded ribbon, a corrugated ribbon, a bendable ribbon or the like. The bendable ribbon is a flexible optical fiber ribbon that can be bent or rolled from a flat shape without deteriorating optical properties of optical fibers. The corrugated ribbon is a ribbon that includes the plurality of optical fiber ribbons coated with a matrix material, where surface of the plurality of optical fiber post the coating of the matrix material becomes a wavy surface or corrugated surface having raised and depressed regions. The intermittently bonded ribbon is a ribbon comprising a plurality of optical fibers bonded intermittently with a special material so that they can be bent and rolled along the width of the intermittently bonded ribbon. The slitted binder 100 is used to loosely bind a bunch of a plurality of optical fibers. The slitted binder 100 is used to loosely bind a bunch/bundle of a plurality of optical fiber ribbons. The slitted binder 100 is utilized to loosely bind the optical fiber ribbon stack. In general, optical fiber ribbon includes number of optical fibers secured or embedded substantially parallel to one another within coating material. In addition, optical fiber ribbons are placed inside optical fiber cables that require high fiber counts within less installation space. In general, optical fiber cables are used to transfer digital data signals in form of light up to distances of hundreds of miles with higher throughput rates than those achievable via electrical communication cables. In general, optical fiber refers to medium associated with transmission of information over long distances in form of light pulses. In addition, the optical fiber uses light to transmit voice and data communications over long distances.
The slitted binder 100 is a coloured binder. Typically, the coloured binder is used for easy identification of ribbon/optical fiber bundles. The slitted binder 100 includes one or more colours to differentiate between the plurality of optical fiber ribbon bundles. The slitted binder 100 includes the one or more colours to differentiate between the plurality of optical fiber bundles. In an example, a single coloured binder is used if number of bunches of optical fibers or ribbons in an optical fiber cable is less than 12. In another example, a combination of at least two or more coloured binders (multiple colours) is used if number of bunches of optical fibers or ribbons in the optical fiber cable is more than 12. The slitted binder 100 is made up of one or more types. The one or more types of the slitted binder 100 may include water swellable element, and one or more repellents. The one or more repellents include moth, termites, and rodent or combination thereof. The slitted binder 100 may be moth repellent, termites repellent, and rodent repellent.
The slitted binder 100 is manufactured using different types of material that is chosen based on type of application or usage. In addition, the type of material includes but may not be limited to natural material, synthetic material, metals and minerals. In an example, the slitted binder 100 is made up of thermoplastic material. In another example, the slitted binder 100 is made up of thermosetting material. In yet another example, the slitted binder 100 is made up of elastomer material. In yet another example, the slitted binder 100 is made up of natural fibers. In addition, the natural fibers include flax, coir, cotton, wood, PLA (maize), mineral (mica), and the like. In yet another example, the slitted binder 100 is made up of any suitable material of the like.
The slitted binder 100 has thickness preferably in range of about 100 microns to 180 microns. Below 100 microns thickness, the slitted binder 100 may be very delicate and beyond 180 microns the binder will occupy more space and increase cable diameter. Also, flexibility of the binder will reduce as we increase thickness. Thickness of the slitted binder 100 may vary as per cable design. The slitted binder 100 has width W preferably in range of about 2 millimeter to 6 millimeter. Below the width of 2 mm, the slitted binder 100 will become mechanically weak to hold the bunch of the plurality of optical fibers, the plurality of optical fiber ribbons, or the optical fiber ribbon stack. Further, above the width of 6 mm, the slitted binder 100 starts experiencing twist issues at un-slitted portions. Also, material consumption and space occupancy will increase. The width W of the slitted binder 100 may vary.
The slitted binder 100 includes plurality of slits 102 along longitudinal direction. The plurality of slits 102 allows the slitted binder 100 to accommodate the bunch of the plurality of optical fibers or the bunch of the plurality of optical fiber ribbons by loosely binding them. The plurality of slits 102 may be formed using mechanical cutter, laser or any other suitable method. The plurality of slits 102 has length L in range of 20 millimeter to 50 millimeter. The length less than 20mm requires very small diameter cop that makes it difficult to pass the bunch of the plurality of optical fibers or the bunch of the plurality of optical fiber ribbons and the length of 50mm is more than sufficient to bind the bundle of very high count optical fibers. The length L of the plurality of slits 102 may vary. In case of rectangular shaped slits, each of the plurality of slits 102 has breadth B1 preferably in a range of about 0.2 millimeter to 0.3 millimeter. Usually, a single fiber is normally of diameter 0.2mm or more and beyond 0.3mm, the slitted binder becomes delicate. Breadth B1 of the plurality of slits 102 may vary.
The plurality of slits 102 may have rectangular shape. In addition, the plurality of slits 102 may have oval shape. Further, the plurality of slits 102 may have circular shape. Furthermore, the plurality of slits 102 may have shape of any polygon or any area bounding closed structure. Moreover, the plurality of slits 102 may have linear shape. Also, the plurality of slits 102 may have shape as that of open or closed contours. Shape of the plurality of slits 102 may vary.
The slitted binder 100 may include one or more small holes 104. In an example, the one or more small holes 104 are positioned between two slits. The one or more small holes 104 make the slitted binder 100 more flexible. In addition, the one or more small holes 104 reduces contact of the plurality of optical fibers and the plurality of optical fiber ribbons with slitted binder 100. Each of the one or more small holes 104 has longest dimension preferably in range of about 3 millimeter to 8 millimeter. Dimension of each of the one or more small holes 104 may vary.
The slitter binder 100 may be placed over a cop (a hollow tube) by passing the cop through to align plurality of slits of the slitted binder in compact serpentine shape. Thereafter, passing the bunch or bundle of the plurality of optical fibers or the bunch or bundle of the plurality of optical fiber ribbons through the cop and joining first edge of the bundle with corresponding first edge of the slitter binder 100 and pull the bundle to stretch the slitter binder 100 over entire length of the bundle. In an example, the slitted binder 100 is used to bind the bundle of up to 1152F. The number of the plurality of optical fibers may vary. A minimum length of cop required for placing the slitted binder can be calculated as: L = (B_i*t)/((s+d)), where, t is binder thickness, Bi is binder length, s is slit size and d is distance between two slits. The binder length can be chosen based on length of the optical fiber cable.
FIG. 2 illustrates an example 200 of the slitted binder 100 with a cylindrical shaped bunch of optical fiber ribbons or optical fibers 202. The slitted binder 100 includes the cylindrical shaped bunch of optical fiber ribbons or optical fibers 202. The cylindrical shaped bunch of optical fiber ribbons or optical fibers 202 is accommodated in the slitted binder 100. The slitted binder 100 is manufactured by providing/creating the plurality of slits to have two slitted arms 204 in the slitted binder 100. The plurality of slits is inserted to create cuts in the slitted binder 100. In addition, cuts in the slitted binder 100 is utilized as a space to accommodate the cylindrical shaped bunch of optical fiber ribbons or optical fibers 202. In addition, end of the slitted binder 100 is tucked with the cylindrical shaped bunch of optical fiber ribbons or optical fibers 202. Further, the cylindrical shaped bunch of optical fiber ribbons or optical fibers 202 is pulled in forward direction in the slitted binder 100. The slitted binder 100 may be made of a material having low shrinkage over heat exposure. The slitted binder 100 may be made of soft material. The slitted binder 100 may be made of a material having strong tensile strength. The slitted binder 100 may be made of any suitable material of the like.
The cylindrical shaped bunch of optical fiber ribbons or optical fibers 202 of the slitted binder 100 has overall diameter A. The overall diameter A of the cylindrical shaped bunch of optical fiber ribbons or optical fibers 202 of the slitted binder 100 is in range of about 1 millimeter to 6.5 millimeter. The overall diameter A of the cylindrical shaped bunch of optical fiber ribbons or optical fibers 202 of the slitted binder 100 may vary. The slitted binder 100 includes un-slitted portion B. Length of un-slitted portion B is preferably in range of about 100 millimeter to 300 millimeter. Un-slitted range less than 100mm will need a very long cop to put the slitted binder. The number of folds will increase, which in turn will require longer cop. Un-slitted length more than 300mm will make binders too loose/free. This may make the handling difficult. Length of un-slitted portion B may vary. In addition, un-slitted portion B is the distance between two slits of the plurality of slits 102. Further, un-slitted portion B has width F in range of about 2 millimeter to 6 millimeter, equal to the width of the binder.
Linear distance C between slitted extremities of one slit of the plurality of slits 102 is in range of about 20 millimeter to 50 millimeter. Linear distance C between slitted extremities of one slit of the plurality of slits 102 may vary. Each of the plurality of slits 102 includes two slitted arms. Width E of each slitted arm of the two slitted arms is in range of about 0.9 millimeter to 2.9 millimeter. Width E of each slitted arm of the two slitted arms may vary.
FIG. 3 is a flow chart 300 illustrating a method for binding the bunch or bundle of the plurality of optical fibers or the bunch or bundle of the plurality of optical fiber ribbons using the slitted binder 100. The slitted binder 100 may loosely bind the bundle to be placed in the optical fiber cable.
At step 302, the method includes providing the plurality of slits 102 along a longitudinal direction, wherein the plurality of slits loosely bind the optical fiber ribbon bundle or a bundle of loose optical fibers. Alternatively, the plurality of slits loosely bind a loose tube bundle. The optical fiber ribbon bundle is a bundle of optical fiber ribbons or a bundle of the loose tubes comprising plurality of optical fibers..
At step 304, the method includes placing the slitted binder 100 over the cop (a hollow tube) by passing the cop through aligned plurality of slits of the slitted binder in a compact serpentine shape.
At step 306, the method includes passing the bunch or bundle of the plurality of optical fibers or the bunch or bundle of the plurality of optical fiber ribbons through the cop and joining first edge of the bundle with corresponding first edge of the slitter binder 100 and pull the bundle to stretch the slitter binder 100 over entire length of the bundle.
In an example, the slitted binder 100 is used to bind the bundle of up to 1152F. The number of the plurality of optical fibers may vary. A minimum length of cop required for placing the slitted binder can be calculated as: L = (B_i*t)/((s+d)), where, t is binder thickness, Bi is binder length, s is slit size and d is distance between two slits.
The various actions, acts, blocks, steps, or the like in the flow chart 300 may be performed in the order presented, in a different order or simultaneously. Further, some of the actions, acts, blocks, steps, or the like may be omitted, added, modified, skipped, or the like without departing from the scope of the invention.
Advantageously, the slitted binder 100 improves space utilization and high density packaging in a high fiber count optical fiber cable. The slitted binder loosely binds the bundle of the plurality of optical fibers, the plurality of optical fiber ribbons, and/or the optical fiber ribbon stack and thus, enables bundle to change its shape, so that ribbon bunch/ fibers bunch can adjust itself in any available space in a cable core. Further, the plurality of slits is made in the slitted binder in longitudinal direction that help in binding the slitted binder over the entire length of the bundle. The optical fiber ribbon can be folded in a serpentine shape such that all the slits align with each other. When the slitted binder is unfolded after passing the bundle of the plurality of optical fibers, the plurality of optical fiber ribbons, and/or the optical fiber ribbon stack through these slits, the slitted binder gets spread over the entire length of the bundle, loosely binding the bundle in the slitted portions spaced apart by the un-slitted length in the slitted binder.
It will be apparent to those skilled in the art that other alternatives of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention. While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific aspect, method, and examples herein. The invention should therefore not be limited by the above described alternative, method, and examples, but by all aspects and methods within the scope of the invention. It is intended that the specification and examples be considered as exemplary, with the true scope of the invention being indicated by the claims.
Conditional language used herein, such as, among others, "can," "may," "might," "may," “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain alternatives include, while other alternatives do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more alternatives or that one or more alternatives necessarily include logic for deciding, with or without other input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular alternative. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth. Also, the term “or” is used in its inclusive sense (and not in its exclusive sense) so that when used, for example, to connect a list of elements, the term “or” means one, some, or all of the elements in the list.
Disjunctive language such as the phrase “at least one of X, Y, Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to present that an item, term, etc., may be either X, Y, or Z, or any combination thereof (e.g., X, Y, and/or Z). Thus, such disjunctive language is not generally intended to, and should not, imply that certain alternatives require at least one of X, at least one of Y, or at least one of Z to each be present.
While the detailed description has shown, described, and pointed out novel features as applied to various alternatives, it can be understood that various omissions, substitutions, and changes in the form and details of the devices or algorithms illustrated can be made without departing from the scope of the disclosure. As can be recognized, certain alternatives described herein can be embodied within a form that does not provide all of the features and benefits set forth herein, as some features can be used or practiced separately from others.

We Claim:

A slitted binder (100) for use in an optical fiber cable, comprising:
a plurality of slits (102) along a longitudinal direction, wherein the plurality of slits loosely bind a plurality of optical fibers or optical fiber ribbons.

The slitted binder (100) as claimed in claim 1 comprising placing the slitted binder over a cop by passing the cop through aligned plurality of slits of the slitted binder in a compact serpentine shape, passing the plurality of optical fibers or optical fiber ribbons through the cop and joining first edge of the plurality of optical fibers or optical fiber ribbons with corresponding first edge of the slitter binder and pulling the plurality of optical fibers or optical fiber ribbons to stretch the slitter binder over entire length of the plurality of optical fiber ribbons.

The slitted binder (100) as claimed in claim 1, wherein a minimum length of the cop required for placing the slitted binder is calculated as:
L = (B_i*t)/((s+d)) ,
where t - binder thickness, Bi - binder length, s - slit size and d – distance between two slits.

The slitted binder (100) as claimed in claim 1, wherein the plurality of slits (102) may have rectangular shape, oval shape, circular shape, polygon shape, any area bounding closed structure, any open and closed contours, straight linear cut.

The slitted binder (100) as claimed in claim 1 comprises one or more holes (104).

The slitted binder (100) as claimed in claim 1, wherein the plurality of slits (102) has a length in a range of 20 millimeter to 50 millimeter and un-slitted binder has a length in a range of 100-300mm.

The slitted binder (100) as claimed in claim 1 is used to bind the plurality of optical fiber ribbons having up to 1152F and is made of a single colour or multiple colours.

A method of binding of a plurality of optical fibers or optical fiber ribbons using a slitted binder (100), comprising:
providing a plurality of slits (102) along a longitudinal direction, wherein the plurality of slits loosely bind the plurality of optical fibers or optical fiber ribbons;
placing the slitted binder over a cop by passing the cop through aligned plurality of slits of the slitted binder in a compact serpentine shape;
passing the plurality of optical fibers or optical fiber ribbons through the cop and joining first edge of the plurality of optical fibers or optical fiber ribbons with corresponding first edge of the slitter binder; and
pulling the plurality of optical fibers or optical fiber ribbons to stretch the slitter binder over entire length of the plurality of optical fibers or optical fiber ribbons.

The method as claimed in claim 8, wherein a minimum length of the cop required for placing the slitted binder is calculated as:
L = (B_i*t)/((s+d)) ,
where t - binder thickness, Bi - binder length, s - slit size and d – distance between two slits.

The method as claimed in claim 8, wherein the plurality of slits (102) may have rectangular shape, oval shape, circular shape, polygon shape, any area bounding closed structure, any open and closed contours, straight linear cut.

The method as claimed in claim 8, wherein the plurality of slits (102) has a length in a range of 20 millimeter to 50 millimeter and un-slitted binder has a length in a range of 100-300mm.

The method as claimed in claim 8, wherein the slitted binder (100) is used to bind the plurality of optical fiber ribbon bundle having up to 1152F and is made of a single colour or multiple colours.