Laser sintered flexible ribbon

Abstract

A rollable optical fiber ribbon includes a plurality of optical transmission elements, wherein each optical transmission element includes an optical core surrounded by a cladding of a different refractive index than the optical core, the cladding surrounded by a fiber coating layer, the fiber coating layer having an inner surface contacting the cladding and an outer surface defining an exterior surface of the optical transmission elements; and a coupling element coupled to and supporting the plurality of optical transmission elements in an array. The coupling element forms a chevron pattern and is formed from a flexible polymeric material such that the plurality of optical transmission elements are reversibly movable from an unrolled position in which the plurality of optical transmission elements are substantially aligned with each other to a rolled position.

What is claimed is: 
     
         1 . An optical fiber cable comprising:
 a jacket defining a central core;   a plurality of optical transmission elements, wherein each optical transmission element includes an optical core surrounded by a cladding of a different refractive index than the optical core, the cladding surrounded by a fiber coating layer, the fiber coating layer having an inner surface contacting the cladding and an outer surface defining an exterior surface of the optical transmission elements; and   a coupling element coupled to and supporting the plurality of optical transmission elements in an array, wherein the coupling element forms a chevron pattern and is formed from a flexible polymeric material such that the plurality of optical transmission elements are reversibly movable from an unrolled position in which the plurality of optical transmission elements are substantially aligned with each other to a rolled position, and wherein the array extends longitudinally through the central core.   
     
     
         2 . The optical fiber cable of  claim 1 , wherein the chevron pattern is continuous across the width of the ribbon. 
     
     
         3 . The optical fiber cable of  claim 2 , wherein the chevron pattern is discontinuous across the width of the ribbon. 
     
     
         4 . The optical fiber cable of  claim 3 , wherein the plurality of optical transmission elements comprises twelve optical fibers. 
     
     
         5 . The optical fiber cable of  claim 4 , wherein at least three pairs of fibers are joined at any one bonding location along a longitudinal length of the ribbon. 
     
     
         6 . The optical fiber cable of  claim 1 , wherein the coupling element comprises a sintered polymer powder 
     
     
         7 . A method of manufacturing an optical fiber ribbon comprising:
 arranging a plurality of optical a plurality of optical transmission elements in parallel to form an array, wherein each optical transmission element includes an optical core surrounded by a cladding of a different refractive index than the optical core, the cladding surrounded by a fiber coating layer, the fiber coating layer having an inner surface contacting the cladding and an outer surface defining an exterior surface of the optical transmission elements;   moving the fiber array longitudinally;   dispensing a polymer powder on the moving fiber array; and   focusing a laser beam onto the moving fiber array such that the laser beam melts the polymer powder to form a polymer coupling element that bonds to the fiber array.   
     
     
         8 . The method of  claim 7 , further comprising forming the coupling element to have chevron pattern that is continuous across the width of the ribbon. 
     
     
         9 . The method of  claim 8 , wherein the chevron pattern is discontinuous across the width of the ribbon. 
     
     
         10 . The method of  claim 9 , wherein the plurality of optical transmission elements comprises twelve optical fibers. 
     
     
         11 . The method of  claim 10 , further comprising joining at least three pairs of optical fibers at any one bonding location along a longitudinal length of the ribbon. 
     
     
         12 . The method of  claim 7 , wherein the polymer powder is a polyamide based powder.