CN110718327B - 一种光电复合缆 - Google Patents
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Abstract
本发明公开了一种光电复合缆,包括缆心和中心加强件(6),其特征在于,所述缆心包括多个电单元(24)和一光单元;每一所述电单元(24)外设有一绝缘层(25),所述光单元包括套管(26)和位于该套管(26)内的若干光纤;所述缆心外纵包一阻水带(3);所述阻水带(3)外依次设有不锈钢带(23)、聚乙烯护套(22)和尼龙护套(21)。本发明的光电复合缆具有各单元固定稳定,既可以满足机械性能,又可满足环境性能等特点。
Description
技术领域
本发明属于通信光缆制造技术领域,涉及一种复合缆,尤其涉及一种光电复合缆。
背景技术
常规的光电复合缆一般采用1+4或1+5结构,如图1所示,其通常采用高强度的辅助加强件,电单元一般为对称的两根或4根,结构一般不圆整,内部的结构单元不易产生相对的滑动,缆芯外用普通镀铬钢带作为保护层,钢带经过轧纹机,压成深度0.5-0.6mm的齿状钢带,钢带易弯曲、容易成型,增加了光缆的弯曲性能,钢带外挤塑一层1.8mm左右的聚乙烯护套料,形成了第一层保护墙,能够顺利通过环境性能和机械性能,但是此光缆外径较大,光缆重量较大,敷设过程中难度较大。
发明内容
针对现有技术中存在的技术问题,本发明的目的在于提供一种光电复合缆。
本发明的技术方案为:
一种光电复合缆,包括缆心和中心加强件6,其特征在于,所述缆心包括多个电单元24和一光单元;每一所述电单元24外设有一绝缘层25,所述光单元包括套管26和位于该套管26内的若干光纤;所述缆心外纵包一阻水带3;所述阻水带3外依次设有不锈钢带23、聚乙烯护套22和尼龙护套21。
进一步的,所述绝缘层25的外径与所述光单元的套管26外径相同或相当;所述光单元内的光纤根数与所述电单元24的个数相同。
进一步的,各所述电单元24和所述光单元通过SZ绞合,形成所述缆芯;相邻所述电单元24之间以及所述电单元24与所述光单元之间填充设定规格线密度的阻水纱。
进一步的,通过6字模纵包工艺在所述阻水带3外纵包一层所述不锈钢带23。
进一步的,所述6字模纵包工艺中的6字模入口设为2°、出口角度设为-4°,6字模成型阻力设置为150-180N;将所述不锈钢带23提前在6字模入口处进行预弯曲,在出口处进行二次卷边、弯曲,然后通过一道定径模进行拱圆处理,二道定径模进行三次拱圆处理,形成完整的圆形结构并在搭接处添加热熔胶。
进一步的,在所述不锈钢带23外采用双层共挤技术制备聚乙烯护套22和尼龙护套21;双层共挤过程中,主挤塑机挤聚乙烯护套料并添加6%-12%的接枝剂,所述接枝剂成分为马来酸酐型聚乙烯;辅机挤塑尼龙护套料。
进一步的,所述聚乙烯护套22为1.0-1.3mm厚度的中密度聚乙烯;所述尼龙护套21为0.4-0.6mm厚度的聚酰胺材料。
进一步的,通过水温梯度冷却方法和速差仪制备所述光单元。
进一步的,所述中心加强件6为膨化钢丝;所述绝缘层25采用交联聚乙烯;所述不锈钢带为通过轧纹机形成扎纹深度0.5-0.8mm的齿状不锈钢带。
一种光电复合缆的制备方法,其步骤包括:对选取的裸光纤着色后进行套塑工序,得到光单元;将所述光单元与多个电单元经过成缆SZ绞合成缆芯,缆芯测试合格之后在缆芯依次外纵包阻水带和不锈钢带,然后在不锈钢带外挤塑聚乙烯和尼龙层。
实现光电复合连接器既可以用电单元连接三级配电柜,也可以用光单元连接室外光交,光电复合连接器必须选择光电复合缆。光电复合缆采用三根导线和3个光单元,通过一系列工序,制备成一种安全性能很高的光电复合缆。
在结构设计过程中,本发明着重考虑以下三点:
A.此种新型的光电复合缆应用场合安全性很高,产品安全性也需满足相关性能。光缆结构中包括电单元,不锈钢带,中心加强件钢丝,为了避免电单元和不锈钢带之间接触,缆芯外纵包一层阻水带,既可以起到屏蔽作用,又可以阻止水纵向渗透。
B. 3个独立的电单元(截面积2.0mm2),加绝缘包层后外径3.0mm,绝缘层材料采用交联聚乙烯(XLPE)代替常规聚乙烯,选用交联聚乙烯使聚乙烯分子由线性结构变为三维网状结构,工作温度提高至90℃,显著提高铜导体的载流能力。使用交联聚乙烯不仅显著提高电单元的机械力学性能、耐热性能、耐环境应力开裂性能、耐化学药品腐蚀性能、抗蠕变性和电性能等综合性能,而且非常明显地提高了其绝缘等级。
C. 3个电单元和一个包含3根光纤的光单元套管(外径3.0mm),通过SZ绞合,形成一个紧凑的缆芯,由于电单元外径和套管外径相同,结构圆整,各单元之间填充一定规格线密度的阻水纱,一般选择3333dtex,保证光缆不渗水。缆芯外纵包阻水带,阻水带后纵包一层不锈钢带,不锈钢带先通过轧纹机形成扎纹深度0.5-0.8mm的齿状不锈钢带,然后通过6字模纵包工艺(包括6字模和双定径模)成型,紧紧包裹缆芯,搭接处用热熔胶填充。在钢带外采用双层共挤技术,挤塑一层1.0-1.3mm厚度的中密度聚乙烯和0.4-0.6mm厚度的聚酰胺材料,为了避免两种材料之间分层,添加接枝剂(马来酸酐型聚乙烯)利用化学反应增加粘结力。此光电复合缆既可以满足基本的机械性能,又可满足环境性能,同时不锈钢带可以起到防鼠性能,聚酰胺外护层起到防蚁功能。
表1新型光电复合缆和传统光电复合缆的对比
光电复合缆生产工艺难点及创新点
(1)套管大管径小余长控制工艺,套管选择3.0mm规格,壁厚达到0.35mm正偏差,余长要求0.3±0.3%,生产过程中难点较大,主要原因是套管采用聚对苯二甲酸丁二醇酯,这种材料是一种结晶材料,后收缩较大。通过水温梯度冷却和增加辅助的速差仪可以满足套管越早结晶,下盘后后收缩越小,余长越容易控制。速差仪处于挤塑机头和主牵引之间,由于速差仪上下轮子的压力,使得机头和速差仪之间的速度大于速差仪和主牵引之间的速度,速差仪与主牵引之间的套管处于松开状态,套管容易结晶,套管强度增加,后收缩减小。多根着色光纤放于光纤放线架,放线张力0.8-1.6N,着色光纤利用集束器把光纤集合,穿过过纤针管和充油针管,利用油膏的压力把光纤输送到套管内,套管余长根据冷却水和速差仪控制,冷却水分为三段(1段35℃,2段30℃,三段22℃),通过梯度冷却法,增加PBT结晶度,减少后收缩。同时速差仪利用上下两个轮子的压力,造成套管的速度差,进一步增加套管的结晶度,减小后收缩,使得余长控制在0.3±0.3%。
(2)不锈钢带纵包工艺,201/304不锈钢是一种通用性的不锈钢材料,防锈能力强,拉伸强度和刚度较大,纵向弯曲阻力大。采用6字模有很大优势,设计6字模入口设为2°、出口角度设为-4°,6字模成型阻力大约150-180N(传统成型模具阻力280-300N),不锈钢带可以提前在6字模入口处进行预弯曲,在出口处进行二次卷边、弯曲,然后通过一道定径模进行拱圆处理,二道定径模进行三次拱圆处理,等到三次拱圆之后,不锈钢带已经形成完整的圆形结构,为了防止不锈钢带扭转开裂,在搭接处添加热熔胶。
(3)聚乙烯和尼龙双层共挤工艺,聚乙烯和尼龙属于两种不同性能的高分子材料,功能也不同。传统的聚乙烯和尼龙护层需要经过两次护套,造成过程和原材料浪费。双层共挤工艺一次性成型,主挤塑机挤聚乙烯护套料(添加6%-12%的接枝剂,接枝剂成分为马来酸酐型聚乙烯),辅机挤塑尼龙护套料,通过接枝剂利用化学交联反应粘结聚乙烯层和尼龙层,使聚乙烯层和尼龙层相互粘结不分离。
与现有技术相比,本发明的积极效果
(1)新型光电复合缆结构圆整,各单元固定稳定;
(2)新型光电复合缆既可以满足机械性能,又可满足环境性能;
(3)新型光电复合缆中的不锈钢带可满足防鼠性能,尼龙护层可满足防蚁性能。
附图说明
图1为传统光电复合缆;
图2为本发明的光电复合缆示意图;
图3为光电复合缆产品工艺路线图。
其中,1-金属复合带,2-缆膏,3-阻水带,4-绝缘垫层,5-馈电线,6-中心加强件,7-纤稿,8-光纤,9-松套管,10-填充绳,11-外护套,21-尼龙护套,22-聚乙烯护套,23-不锈钢带,24-电单元,25-绝缘层,26-套管。
具体实施方式
下面对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明的保护范围。
光电复合缆光缆结构图如图2所示,包括缆心和中心加强件6,缆心包括多个电单元24和一光单元;每一电单元24外设有一绝缘层25,光单元包括套管26和位于该套管26内的若干光纤;缆心外纵包一阻水带3;阻水带3外依次设有不锈钢带23、聚乙烯护套22和尼龙护套21。
本发明的光电复合缆中绝缘层25的外径与光单元的套管26外径相同或相当,从而结构圆整,各单元之间填充一定规格线密度的阻水纱,一般选择3333dtex,保证光缆不渗水。光单元内包括3根光纤,光电复合缆中包括三个电单元24。电单元24和光单元通过SZ绞合,形成缆芯。
本发明的光电复合缆制备过程中,通过6字模纵包工艺在阻水带3外纵包一层不锈钢带23;纵包不锈钢带时,6字模纵包工艺中的6字模入口设为2°、出口角度设为-4°,6字模成型阻力设置为150-180N;将不锈钢带23提前在6字模入口处进行预弯曲,在出口处进行二次卷边、弯曲,然后通过一道定径模进行拱圆处理,二道定径模进行三次拱圆处理,形成完整的圆形结构并在搭接处添加热熔胶。
本发明的光电复合缆制备过程中,在不锈钢带23外采用双层共挤技术制备聚乙烯护套22和尼龙护套21;双层共挤过程中,主挤塑机挤聚乙烯护套料并添加6%-12%的接枝剂,其中接枝剂成分为马来酸酐型聚乙烯;辅机挤塑尼龙护套料;聚乙烯护套22为1.0-1.3mm厚度的中密度聚乙烯;尼龙护套21为0.4-0.6mm厚度的聚酰胺材料。
本发明的光电复合缆的中心加强件6为膨化钢丝;绝缘层25采用交联聚乙烯。
新型光电复合缆结构的生产工艺路线图如图3所示,裸光纤检测衰减、纤芯包层同心度、宏弯损耗等测试合格之后,经过入口模和定径模,利用着色油墨进行着色,着色完成后,测试油墨固化度和光纤衰减性能。着色光纤合格后,经过二次套塑工序,用高强度聚对苯二甲酸丁二醇酯和油膏保护光纤,形成套管,检测套管和外径、壁厚、光纤衰减性能。测试合格之后,把套管(光单元)和合格的3根电单元经过成缆SZ绞合成缆芯,测试缆芯的绞合节距和光纤的衰减。测试合格之后,在护套机台,缆芯外纵包阻水带,阻水带后纵包不锈钢带,不锈钢带外挤塑聚乙烯和尼龙层,保证聚乙烯层和尼龙层粘结不分离,制备得到新型的光电复合缆。成品测试光单元的衰减和电单元的衰减、电阻。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明披露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应该以权利要求书的保护范围为准。
Claims (6)
1.一种光电复合缆,包括缆芯和中心加强件(6),其特征在于,所述缆芯包括三个电单元(24)和一光单元;每一所述电单元(24)外设有一绝缘层(25),所述光单元包括套管(26)和位于该套管(26)内的若干光纤;所述缆芯外纵包一阻水带(3);所述阻水带(3)外依次设有不锈钢带(23)、聚乙烯护套(22)和尼龙护套(21);各所述电单元(24)和所述光单元通过SZ绞合,形成所述缆芯;相邻所述电单元(24)之间以及所述电单元(24)与所述光单元之间填充设定规格线密度的阻水纱;在所述不锈钢带(23)外采用双层共挤技术制备聚乙烯护套(22)和尼龙护套(21);双层共挤过程中,主挤塑机挤聚乙烯护套料并添加6%-12%的接枝剂,所述接枝剂成分为马来酸酐型聚乙烯;辅机挤塑尼龙护套料;所述聚乙烯护套(22)为1.0-1.3mm厚度的中密度聚乙烯;所述尼龙护套(21)为0.4-0.6mm厚度的聚酰胺材料;所述绝缘层(25)采用交联聚乙烯;所述套管(26)采用聚对苯二甲酸丁二醇酯,通过水温梯度冷却方法和速差仪制备所述光单元,套管选择3.0mm规格,壁厚达到0.35mm正偏差,余长要求0.3±0.3%;速差仪处于挤塑机头和主牵引之间,基于速差仪上下轮子的压力,使得机头和速差仪之间的速度大于速差仪和主牵引之间的速度,从而使得速差仪与主牵引之间的套管处于松开状态;然后利用集束器将光纤集合,穿过过纤针管和充油针管,利用油膏的压力把光纤输送到套管内,套管余长根据冷却水和速差仪控制,冷却水分为三段,其中第一段35℃、第二段30℃、第三段22℃。
2.如权利要求1所述的光电复合缆,其特征在于,所述绝缘层(25)的外径与所述光单元的套管(26)外径相同或相当;所述光单元内的光纤根数与所述电单元(24)的个数相同。
3.如权利要求1所述的光电复合缆,其特征在于,通过6字模纵包工艺在所述阻水带(3)外纵包一层所述不锈钢带(23)。
4.如权利要求3所述的光电复合缆,其特征在于,所述6字模纵包工艺中的6字模入口设为2°、出口角度设为-4°,6字模成型阻力设置为150-180N;将所述不锈钢带(23)提前在6字模入口处进行预弯曲,在出口处进行二次卷边、弯曲,然后通过一道定径模进行拱圆处理,二道定径模进行三次拱圆处理,形成完整的圆形结构并在搭接处添加热熔胶。
5.如权利要求1所述的光电复合缆,其特征在于,所述中心加强件(6)为膨化钢丝;所述不锈钢带为通过轧纹机形成扎纹深度0.5-0.8mm的齿状不锈钢带。
6.一种光电复合缆的制备方法,其步骤包括:对选取的裸光纤着色后进行套塑工序,在光纤外形成套管(26),得到光单元;将所述光单元与三个电单元(24)经过成缆SZ绞合成缆芯,每一所述电单元(24)外设有一绝缘层(25),缆芯测试合格之后在缆芯依次外纵包阻水带和不锈钢带(23),然后在不锈钢带外挤塑聚乙烯和尼龙层;其中相邻所述电单元(24)之间以及所述电单元(24)与所述光单元之间填充设定规格线密度的阻水纱;在所述不锈钢带(23)外采用双层共挤技术制备聚乙烯护套(22)和尼龙护套(21);双层共挤过程中,主挤塑机挤聚乙烯护套料并添加6%-12%的接枝剂,所述接枝剂成分为马来酸酐型聚乙烯;辅机挤塑尼龙护套料;所述聚乙烯护套(22)为1.0-1.3mm厚度的中密度聚乙烯;所述尼龙护套(21)为0.4-0.6mm厚度的聚酰胺材料;所述绝缘层(25)采用交联聚乙烯;所述套管(26)采用聚对苯二甲酸丁二醇酯,通过水温梯度冷却方法和速差仪制备所述光单元,套管选择3.0mm规格,壁厚达到0.35mm正偏差,余长要求0.3±0.3%;速差仪处于挤塑机头和主牵引之间,基于速差仪上下轮子的压力,使得机头和速差仪之间的速度大于速差仪和主牵引之间的速度,从而使得速差仪与主牵引之间的套管处于松开状态;然后利用集束器将光纤集合,穿过过纤针管和充油针管,利用油膏的压力把光纤输送到套管内,套管余长根据冷却水和速差仪控制,冷却水分为三段,其中第一段35℃、第二段30℃、第三段22℃。
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