The present invention provides a method for reducing and/or controlling the variations
of excess fiber length along the length of reeled fiber optic buffer tubes during
the manufacture of the buffer tubes. The present invention varies any number, or
combination, of parameters during the manufacture of buffer tubes to achieve a
substantially uniform excess fiber length along a reeled buffer tube. One embodiment
of the inventive method uses monotonically decaying draw or take-up tension of
the buffer tubes during winding, combined with a stiffness-compliant pad placed
on the reel core to aid in providing a substantially uniform excess fiber length
in the tube, while another embodiment uses a monotonically increasing angular speed
of the reel in combination with the stiffness-compliant pad on the reel core. In
yet another embodiment a pad is placed either periodically or continuously in the
windings of the buffer tube to provide an absorbing layer for the residual stresses
existing in the buffer tube as it is reeled and after the reeling is complete,
combined with re-reeling the buffer tube onto a second reel after the buffer tube
has cooled (after manufacture), where the pad is removed during the re-reeling
process. Additionally, the present invention can have the layers of buffer tube
separated with rigid, cylindrical panels separating the layers. The present inventive
method also combines any, or all, of the above steps to aid in achieving a substantially
uniform excess fiber length along the length of the reeled buffer tube.
