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H3C Fiber Optic Hybrid Cable Connector Manufacturing Method

Fiber and communications infrastructure knowledge brief Published 12 Mar 2022

Prepared for preliminary research by the ALFA PRO knowledge desk. Confirm optical interfaces, port or core capacity, electrical input and output, enclosure protection, thermal design and installation limits against current standards and product documentation.

H3C fiber optic hybrid cable connectors are manufactured by integrating optical fibers and copper conductors into a single hybrid assembly, typically using pigtail cords, fusion splicing, and modular connector components.Hybrid Cable Structure

H3C hybrid cables combine optical fibers and copper wires in a single cable to provide both data transmission and PoE power supply. The cable consists of a main cable for long-distance runs and pigtail cords at each end, which terminate in optical-electric hybrid connectors. The main cable does not have pre-installed connectors, allowing flexible on-site termination .

Connector Assembly Process
  1. Pigtail Preparation: Pigtail cords contain two optical fibers and two copper wires. One end of the pigtail has a hybrid connector, while the other end is prepared for fusion splicing to the main cable .
  2. Fusion Splicing: The optical fibers of the main cable are fusion spliced to the fibers of the pigtail cord. Best practice involves splicing fibers of the same color at the switch side and different colors at the powered device side to prevent misalignment .
  3. Copper Wire Termination: The copper conductors in the main cable are connected to the corresponding copper wires in the pigtail cord, typically using crimping or soldering methods depending on the connector design .
  4. Hybrid Connector Integration: The pigtail cord is terminated with a hybrid optical-electric connector (PDLC connector for second-generation cables), which allows simultaneous data and power transmission when plugged into a hybrid optical-electrical port .
  5. Optional Fiber Jumpers: For neat cabling in equipment rooms, fiber jumpers with hybrid connectors at both ends can be used to connect devices or distribution frames .
Second-Generation Hybrid Cable Considerations

Second-generation H3C hybrid cables (V2.0) integrate optical fibers and copper conductors during termination, simplifying installation. Only a single hybrid connector is required at each end, unlike first-generation cables that require separate LC and RJ45 connectors . Pigtails or fiber jumpers can be fusion spliced to either first- or second-generation main cables.

Repair and Modularity

Hybrid fiber/copper connector assemblies are designed to allow repair of damaged fibers or copper conductors without replacing the entire connector or cable. Individual connectors can be converted between genders or reconfigured as fiber-only or copper-only connectors, enhancing flexibility and reducing maintenance costs .

Summary

The manufacturing and assembly of H3C fiber optic hybrid cable connectors involve:

  • Preparing pigtail cords with hybrid connectors
  • Fusion splicing optical fibers to the main cable
  • Terminating copper conductors to match the main cable
  • Integrating the hybrid connector for combined data and power
  • Optional use of fiber jumpers for structured cabling
  • Modular design for repair and reconfiguration This method ensures reliable, flexible, and cost-effective deployment of hybrid optical-electrical networks.

H3C Fiber Optic Hybrid Cable Connector Manufacturing Method - ALFA PRO COMMUNICATION SYSTEMS (Pty) Ltd [PDF]

H3C Fiber Optic Hybrid Cable Connector Manufacturing Method

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This reference is intended for preliminary fiber and communications infrastructure research. Optical interface, fiber type, port or core capacity, electrical input and output, enclosure protection, cooling, installation limits and applicable standards must be verified for the specific project.

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