CN114114575A - Production process of thermal-formed optical cable - Google Patents
Production process of thermal-formed optical cable Download PDFInfo
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- CN114114575A CN114114575A CN202111510773.0A CN202111510773A CN114114575A CN 114114575 A CN114114575 A CN 114114575A CN 202111510773 A CN202111510773 A CN 202111510773A CN 114114575 A CN114114575 A CN 114114575A
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- 230000003287 optical effect Effects 0.000 title claims abstract description 103
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 239000013307 optical fiber Substances 0.000 claims abstract description 66
- 239000003292 glue Substances 0.000 claims abstract description 51
- 239000003822 epoxy resin Substances 0.000 claims abstract description 20
- 229920000647 polyepoxide Polymers 0.000 claims abstract description 20
- 239000000835 fiber Substances 0.000 claims abstract description 10
- 239000007788 liquid Substances 0.000 claims abstract description 7
- 238000007598 dipping method Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 27
- 239000003795 chemical substances by application Substances 0.000 claims description 17
- 239000000203 mixture Substances 0.000 claims description 14
- 239000000945 filler Substances 0.000 claims description 10
- 238000000465 moulding Methods 0.000 claims description 9
- 239000000853 adhesive Substances 0.000 claims description 7
- 230000001070 adhesive effect Effects 0.000 claims description 7
- 238000004804 winding Methods 0.000 claims description 7
- 238000005452 bending Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 5
- 239000000843 powder Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 5
- 239000003365 glass fiber Substances 0.000 claims description 4
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 3
- 239000004760 aramid Substances 0.000 claims description 3
- 229920003235 aromatic polyamide Polymers 0.000 claims description 3
- 239000004917 carbon fiber Substances 0.000 claims description 3
- 238000010924 continuous production Methods 0.000 claims description 3
- 230000000694 effects Effects 0.000 claims description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 3
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- 230000001360 synchronised effect Effects 0.000 claims description 3
- 229920001187 thermosetting polymer Polymers 0.000 claims description 3
- 230000003044 adaptive effect Effects 0.000 claims description 2
- 238000009472 formulation Methods 0.000 claims 1
- 238000005516 engineering process Methods 0.000 abstract description 13
- 230000035882 stress Effects 0.000 description 10
- 238000004891 communication Methods 0.000 description 6
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- 238000011161 development Methods 0.000 description 3
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- RAXXELZNTBOGNW-UHFFFAOYSA-N imidazole Natural products C1=CNC=N1 RAXXELZNTBOGNW-UHFFFAOYSA-N 0.000 description 3
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- 230000005540 biological transmission Effects 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 150000008065 acid anhydrides Chemical class 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 229920006335 epoxy glue Polymers 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
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- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4479—Manufacturing methods of optical cables
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D11/00—Producing optical elements, e.g. lenses or prisms
- B29D11/00663—Production of light guides
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
- Ophthalmology & Optometry (AREA)
- Mechanical Engineering (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Ropes Or Cables (AREA)
Abstract
The invention discloses a thermal forming optical cable production process, and relates to the technical field of optical cable production. The invention comprises the following steps: bundling optical fibers and yarns on a first yarn guide plate through an optical fiber pay-off device and a fiber pay-off device; secondly, guiding the optical fibers and the yarns on the first yarn guide plate into a glue tank through a yarn guide hole for glue dipping, so that the yarns are filled with epoxy resin glue mixed liquid with a special formula; step three, the fully gummed yarns are gathered on a second yarn guide plate along the glue guide holes, so that the yarns and the optical fibers are arranged according to a preset sequence; and fourthly, converging the optical fibers and the yarns soaked with the glue through a second yarn guide plate, and sequentially entering a preforming die and a forming die. The invention adopts the full tight-sleeve technology, so that the optical cable and the reinforced fiber are completely combined into a whole through the epoxy resin, and the performance of most sensing optical cables such as stress sensing, temperature sensing and vibration sensing is greatly improved.
Description
Technical Field
The invention belongs to the technical field of optical cable production, and particularly relates to a thermal forming optical cable production process.
Background
With the development of optical technology, the application of optical fiber cables has not only been widely applied in the communication field, such as modern 4G and 5G technologies, but also based on optical fiber cables as transmission media. The development of the sensing technology of the optical fiber opens another piece of optical fiber to be wider. Optical fiber sensing technology has been developed to monitor various basic physical quantities such as temperature, sound, vibration, stress, displacement, electromagnetic interference, etc. Different from the cabling technology of the prior communication optical cable, the sensing optical cable has the complexity degree far higher than that of the common communication optical cable due to different realization principles, use environments and installation modes. The final purposes of various materials, structures and packaging modes adopted by the common communication optical cable are to ensure normal long-distance communication of the optical fiber, reduce the loss of the optical cable from the outside, improve the transmission performance of the optical fiber and prolong the service life of the optical fiber. The design of the cable is such that the cable can be reliably used in different environments. The purpose of development of the sensing optical cable is not to communicate, but to monitor stresses such as temperature, vibration frequency, amplitude, longitudinal tension, compression, macrobending and the like, and to monitor the basic physical quantities.
Thus, the optical sensing cable is more concerned with how to make the optical fiber a stable and sensitive sensor, and then the service life of the optical fiber. This involves a shift in the way the optical fiber is bonded to various materials. The difference of the emphasis points makes the traditional production technology of the communication optical cable unable to meet the requirements of the novel sensing optical cable.
Disclosure of Invention
The invention aims to provide a production process of a thermal-formed optical cable, which solves the technical problems of stability and sensitivity of a sensing optical cable.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a production process of a thermal-formed optical cable comprises the following steps:
bundling optical fibers and yarns on a first yarn guide plate through an optical fiber pay-off device and a fiber pay-off device;
secondly, guiding the optical fibers and the yarns on the first yarn guide plate into a glue tank through a yarn guide hole for glue dipping, so that the yarns are filled with epoxy resin glue mixed liquid with a special formula;
step three, the fully gummed yarns are gathered on a second yarn guide plate along the glue guide holes, so that the yarns and the optical fibers are arranged according to a preset sequence;
fourthly, the optical fibers and the yarns soaked with the glue are gathered together through a second yarn guide plate and sequentially enter a preforming die and a forming die;
step five, the optical fiber and the yarn are cured at high temperature in the forming die, and the optical fiber, the yarn, the epoxy resin adhesive and the modified filler are completely combined together to form an optical cable with certain strength;
the molded optical cable is driven by a tractor, the tractor continuously rotates to pull the finished optical cable to continuously come out of the molding die, and yarns and optical fibers in front of the molding die continuously enter the molding die, so that a continuous production process is formed;
and step seven, after the optical cable is cooled and pulled by a tractor, the optical cable is wound by a winding device.
Optionally, in the third step, before the yarn enters the eyelet of the second yarn guide plate, the yarn passes through a glue scraper to remove excess glue, and the yarn returns to the glue groove through the recovery plate of the glue groove to be used continuously.
Optionally, after the optical cable comes out of the forming die in the fifth step, the temperature of the optical cable is 170-200 ℃, and a distance of 2-3 meters is kept between the forming die and the tractor for natural cooling of the optical cable.
Optionally, in the fifth step, air cooling equipment is added between the forming die and the tractor, so that the optical cable can be rapidly cooled to normal temperature.
Optionally, the winding device in the seventh step has adaptive tension adjustment and automatic start and stop functions to ensure that the optical cable is received on the wire coil according to a certain constant tension, and simultaneously, the speed of winding up and the speed of production can be synchronized.
Optionally, 2-10 KG of thermosetting epoxy resin glue mixed liquid is placed in the glue groove, and the resin glue is composed of a certain amount of epoxy resin, a curing agent, a release agent and other modified fillers.
Optionally, the glue mixture in the glue groove mainly comprises the following components in percentage by mass: 85% of epoxy resin, 2-3% of curing agent, 3-5% of release agent and 10-20% of powder filler.
Alternatively, the processing time of the glue mixture is 4 hours, with the best results within 2 hours, so the amount of glue can be determined by the speed and time of consumption.
Optionally, the optical fiber is a single-mode optical fiber or a multimode optical fiber with bending resistance, such as G657a1/G657a2/G657B3 with good bending resistance.
Optionally, the yarn is glass fiber of untwisted filaments, and the raw material of the glass fiber is one or a mixture of carbon fiber yarn and aramid yarn with high strength.
The embodiment of the invention has the following beneficial effects:
1. the invention adopts a complete tight-sleeving technology, so that the optical cable and the reinforcing fiber are completely combined into a whole through epoxy resin, and the performance of most sensing optical cables such as stress sensing, temperature sensing and vibration sensing is greatly improved. Particularly, the conventional loose tube process cannot be applied to the production of the stress sensing optical cable due to the requirement of stress sensing.
2. According to the thermal forming process, the proportion of the glue mixture is adjusted, so that the shrinkage rate in the thermal forming process can be controlled, and the purpose of generating optical cables with different purposes is achieved.
3. The optical fiber produced by the thermal forming process has high stability and consistency, and is particularly suitable for manufacturing the sensing optical cable with high requirement on the consistency of the optical fiber performance.
4. The invention makes the strength of the optical cable far higher than the common strength through the reinforcement of the fiber, and can make the outer diameter of the optical cable very small, so that the optical cable has larger installation space and more flexible installation mode.
5. The invention can simultaneously produce multiple wires, is different from the single wire production of the traditional optical cable process, can simultaneously produce 32 optical cables theoretically, and has the efficiency far higher than the production technology of the common optical cables.
6. The technology of the invention can be used for the packaging of continuous fiber gratings besides the manufacturing of the sensing optical cable.
7. The invention can be used for manufacturing conventional round optical cables and also can be used for manufacturing special-shaped optical cables with various cross-sectional shapes by changing the forming die so as to meet various individual requirements of the sensing optical cable, particularly fields which cannot be suitable for some round optical cables.
8. The invention can easily realize that the optical fibers in the optical cable can be regularly arranged in the optical cable according to a certain sequence and fixed positions without generating the phenomena of crossing, dislocation and the like, and has very important function for application scenes with directionality, such as stress, displacement, vibration, sonar and the like, which need to know the direction of a source end.
Of course, it is not necessary for any product in which the invention is practiced to achieve all of the above-described advantages at the same time.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic diagram of an apparatus according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.
To maintain the following description of the embodiments of the present invention clear and concise, a detailed description of known functions and known components of the invention have been omitted.
Referring to fig. 1, in this embodiment, a process for producing a thermoformed optical cable is provided, which includes: the method comprises the following steps:
bundling optical fibers and yarns on a first yarn guide plate through an optical fiber pay-off device and a fiber pay-off device;
secondly, guiding the optical fibers and the yarns on the first yarn guide plate into a glue tank through a yarn guide hole for glue dipping, so that the yarns are filled with epoxy resin glue mixed liquid with a special formula;
step three, the fully gummed yarns are gathered on a second yarn guide plate along a glue guide hole, so that the yarns and the optical fibers have a preset sequence, wherein before the yarns enter the holes of the second yarn guide plate, the yarns pass through a glue scraper, redundant glue is removed, and the yarns return to a glue groove through a recovery plate of the glue groove for continuous use;
fourthly, the optical fibers and the yarns soaked with the glue are gathered together through a second yarn guide plate and sequentially enter a preforming die and a forming die;
step five, the optical fiber and the yarn are cured at high temperature in the forming die, the optical fiber, the yarn, the epoxy resin adhesive and the modified filler are completely combined together to form an optical cable with certain strength, wherein the optical cable has the high temperature of 170-200 ℃ after coming out of the forming die, the distance between the forming die and a tractor is kept between 2-3 meters, and the optical cable is used for natural cooling of the optical cable, or air cooling equipment is added between the forming die and the tractor, so that the optical cable can be rapidly cooled to the normal temperature;
the molded optical cable is driven by a tractor, the tractor continuously rotates to pull the finished optical cable to continuously come out of the molding die, and yarns and optical fibers in front of the molding die continuously enter the molding die, so that a continuous production process is formed;
and step seven, after the optical cable is cooled and pulled by the tractor, the optical cable is wound by the winding device, and the winding device has self-adaptive tension regulation and automatic start and stop functions so as to ensure that the optical cable is received on the wire coil according to a certain constant tension and ensure that the winding speed and the production speed can be synchronous.
2~10 KG's thermosetting epoxy glue mixed liquid is placed to the gluey inslot of this embodiment, and the resin glue comprises a certain amount of epoxy, curing agent, release agent and other modified fillers.
The typical components of the glue mixture in the glue tank of the embodiment mainly comprise the following components in percentage by mass: 85% of epoxy resin, 2-3% of curing agent, 3-5% of release agent and 10-20% of powder filler, wherein the epoxy resin is used as a main raw material, the epoxy resin has the advantages of excellent environmental characteristics, higher use temperature, smaller shrinkage, ultraviolet aging resistance and the like, and the epoxy resin is preferably used as a main adhesive. The curing agent is generally some peroxide with stronger activity, and acid anhydride, tertiary amine and imidazole curing agents are commonly used. The release agent used in the invention is an internal release agent which is in a liquid state at normal temperature and can be directly mixed with resin glue, and the internal release agent is exuded and diffused from a resin matrix to the surface of a finished product under a certain temperature condition to form an isolating film between a mould and an optical cable finished product, thereby reducing the friction between a forming mould and the finished optical cable and ensuring the smooth surface of the finished product. The customary mold release agents are usually mixtures of copolymers of primary, secondary and organic phosphates with fatty acids.
The powder filler is usually a very fine powder such as aluminum hydroxide to fill or improve the hardness of the finished cable;
the processing time of the glue mixture is 4 hours, the effect is optimal within 2 hours, so the dosage of the glue can be determined according to the consumption speed and time.
The optical fiber of the embodiment adopts a single mode optical fiber or a multimode optical fiber with bending resistance, such as G657A1/G657A2/G657B3 and the like with good bending resistance.
The yarn of this embodiment is glass fiber of untwisted filaments, and one or a mixture of a carbon fiber yarn and a yarn having a high aramid yarn strength may be used.
1. The optical fiber is different from the prior loose-tube optical fiber structure, under the loose-tube optical fiber structure, factice is usually filled between the optical fiber and the sleeve, and the optical fiber and the sleeve cannot be tightly combined. Therefore, some technical requirements for tight combination of the optical fiber and the outer sheath material cannot be met. The present invention is designed specifically for this deficiency. The invention adopts a complete tight-sleeving technology, so that the optical fiber and the reinforced fiber are completely combined into a whole through epoxy resin, and the performance of most sensing optical cables such as stress sensing, temperature sensing and vibration sensing is greatly improved. Particularly, the conventional loose tube process cannot be applied to the production of the stress sensing optical cable due to the requirement of stress sensing.
2. According to the thermal forming process, the proportion of the glue mixture is adjusted, so that the shrinkage rate in the thermal forming process can be controlled, and the purpose of generating optical cables with different purposes is achieved.
3. The optical fiber produced by the thermal forming process has high stability and consistency, and is particularly suitable for manufacturing the sensing optical cable with high requirement on the consistency of the optical fiber performance.
4. The strength of the optical cable is far higher than that of the optical cable by reinforcing the through-edge fibers, the outer diameter of the optical cable can be made very small, and the optical cable has larger installation space and more flexible installation mode.
5. The invention can simultaneously produce multiple wires, is different from the single wire production of the traditional optical cable process, can simultaneously produce 32 optical cables theoretically, and has the efficiency far higher than the production technology of the common optical cables.
6. In addition to conventional cable manufacturing, the techniques of the present invention may also be used for the encapsulation of continuous fiber gratings.
7. The traditional optical cable manufacturing technology can only produce circular (or oval) optical cables generally, and besides the conventional circular optical cables, the special-shaped optical cables with various cross-sectional shapes can be manufactured by changing a forming die, so that various individual requirements of the sensing optical cables are met, and particularly, fields which cannot be suitable for some circular optical cables are met.
8. The optical fiber cable is different from a traditional bundle optical cable structure, optical fibers cannot be regularly sequenced in the whole optical cable according to a certain sequence, the optical fiber cable can easily realize the point, the optical fibers in the optical cable can be regularly arranged in the optical cable according to a certain sequence and fixed positions, and phenomena of crossing, dislocation and the like cannot be generated, so that the optical fiber cable has very important function for application scenes with directivity, such as stress, displacement, vibration, sonar and the like, which need to know the direction and the source end.
The above embodiments may be combined with each other.
It should be noted that the terms "first," "second," and the like in the description and claims of this application and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the application described herein are capable of operation in sequences other than those illustrated or described herein.
In the description of the present invention, it is to be understood that the orientation or positional relationship indicated by the orientation words such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc. are usually based on the orientation or positional relationship shown in the drawings, and are only for convenience of description and simplicity of description, and in the case of not making a reverse description, these orientation words do not indicate and imply that the device or element being referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore, should not be considered as limiting the scope of the present invention; the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
Claims (10)
1. A process for producing a thermoformed optical cable, comprising: the method comprises the following steps:
bundling optical fibers and yarns on a first yarn guide plate through an optical fiber pay-off device and a fiber pay-off device;
secondly, guiding the optical fibers and the yarns on the first yarn guide plate into a glue tank through a yarn guide hole for glue dipping, so that the yarns are filled with epoxy resin glue mixed liquid with a special formula;
step three, the fully gummed yarns are gathered on a second yarn guide plate along the glue guide holes, so that the yarns and the optical fibers are arranged according to a preset sequence;
fourthly, the optical fibers and the yarns soaked with the glue are gathered together through a second yarn guide plate and sequentially enter a preforming die and a forming die;
step five, the optical fiber and the yarn are cured at high temperature in the forming die, and the optical fiber, the yarn, the epoxy resin adhesive and the modified filler are completely combined together to form an optical cable with certain strength;
the molded optical cable is driven by a tractor, the tractor continuously rotates to pull the finished optical cable to continuously come out of the molding die, and yarns and optical fibers in front of the molding die continuously enter the molding die, so that a continuous production process is formed;
and step seven, after the optical cable is cooled and pulled by a tractor, the optical cable is wound by a winding device.
2. A process for manufacturing a thermoformed optical cable according to claim 1, wherein in step three, before the yarn enters the holes of the second yarn guide, the yarn passes through a stripper to remove excess glue and returns to the glue tank through the recovery plate of the glue tank for further use.
3. A process for manufacturing a thermoformed optical cable according to claim 1, wherein in the fifth step, the optical cable has a high temperature of 170-200 ℃ after coming out of the forming mold, and the distance between the forming mold and the drawing machine is 2-3 m, so as to cool the optical cable naturally.
4. A process for manufacturing a thermoformed optical cable according to claim 1 wherein in step five, an air cooling device is added between the forming die and the drawing machine so that the optical cable can be rapidly cooled to normal temperature.
5. A process for manufacturing a thermoformed optical cable as claimed in claim 1, wherein in step seven the winder has adaptive tension adjustment and automatic start and stop functions to ensure that the optical cable is wound onto the reel with a constant tension and that the take-up speed is synchronized with the production speed.
6. The process for producing a thermoformed optical cable according to claim 1, wherein 2 to 10KG of a thermosetting epoxy resin adhesive mixture is placed in the adhesive tank, and the resin adhesive mixture comprises a predetermined amount of epoxy resin, a curing agent, a release agent and other modified fillers.
7. The process for producing a thermoformed optical cable according to claim 1, wherein the glue mixture in the glue groove comprises, in mass percent: 85% of epoxy resin, 2-3% of curing agent, 3-5% of release agent and 10-20% of powder filler, and different glue formulations can enable the finished optical cable to have different performances and meet the requirements of different application scenes.
8. A process for manufacturing a thermoformed optical cable as claimed in claim 7, wherein the processing time of the glue mixture is 4 hours, with the optimum effect being achieved within 2 hours, so that the amount of glue used can be determined by the speed and time of consumption.
9. A process for manufacturing a thermoformed optical cable according to claim 1, wherein the optical fiber is a single mode optical fiber such as G657A1/G657A2/G657B3 or a multimode optical fiber having bending resistance.
10. A process for manufacturing a thermoformed optical cable according to claim 1 wherein the yarns are generally glass fibers of untwisted filaments, and may be one or more of carbon fiber yarns and aramid yarn of high strength.
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| CN111257993A (en) * | 2020-02-26 | 2020-06-09 | 山东大学 | Fiber grating strain sensor, fiber grating strain sensor assembly, forming method and application of fiber grating strain sensor assembly |
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