CN117492154A - Tight sleeve optical unit, special optical cable comprising same and preparation methods of tight sleeve optical unit and special optical cable - Google Patents
Tight sleeve optical unit, special optical cable comprising same and preparation methods of tight sleeve optical unit and special optical cable Download PDFInfo
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- CN117492154A CN117492154A CN202311430262.7A CN202311430262A CN117492154A CN 117492154 A CN117492154 A CN 117492154A CN 202311430262 A CN202311430262 A CN 202311430262A CN 117492154 A CN117492154 A CN 117492154A
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Classifications
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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
- G02B6/4401—Optical cables
- G02B6/4429—Means specially adapted for strengthening or protecting the cables
- G02B6/443—Protective covering
-
- 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
- G02B6/4401—Optical cables
- G02B6/4429—Means specially adapted for strengthening or protecting the cables
- G02B6/443—Protective covering
- G02B6/4432—Protective covering with fibre reinforcements
-
- 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
- G02B6/4401—Optical cables
- G02B6/4429—Means specially adapted for strengthening or protecting the cables
- G02B6/4434—Central member to take up tensile loads
-
- 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
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Light Guides In General And Applications Therefor (AREA)
Abstract
The invention discloses a tight-buffered optical unit, a special optical cable comprising the tight-buffered optical unit and a preparation method of the tight-buffered optical unit and the special optical cable, and belongs to the technical field of special optical cables. The tight sleeve optical unit and the special optical cable woven based on the tight sleeve optical unit are simple in structure and convenient to prepare, the tensile strength of the tight sleeve optical unit and the special optical cable can be fully ensured, the forming process of the optical cable is simplified, the unit weight of the optical cable is reduced, the problems of difficult midway branching, large long-distance laying difficulty and high cost of the traditional optical cable are overcome, the service performance of the special optical cable is effectively ensured, the waste of optical fiber materials in the use process of the special optical cable is reduced, the application cost of the optical cable is reduced, and the tight sleeve optical cable has good practical value.
Description
Technical Field
The invention belongs to the technical field of special optical cables, and particularly relates to a tight-buffered optical unit, a special optical cable comprising the tight-buffered optical unit and preparation methods of the tight-buffered optical unit and the special optical cable.
Background
With the gradual maturity of the optical fiber cable technology, the application field of the optical fiber cable is further widened, and higher requirements are put on the functional characteristics and the service performance of the optical fiber cable, such as long-distance arrangement requirements or rapid branching requirements of the optical fiber cable.
For the conventional optical cable, because the outer diameter of the optical cable is larger, and the outer periphery of the optical cable is generally provided with an outer sheath/outer protective layer, an armor layer, an outer coating layer and the like, the unit weight of the optical cable is larger, the one-time laying distance is usually not more than 3km, and the long-distance laying requirement of more than 10km under the novel laying requirement is difficult to meet; if long-distance laying is not to be performed, special laying equipment needs to be introduced, and thus the optical cable laying cost and the application cost are increased. Meanwhile, as the outer periphery of the optical unit of the conventional optical cable is provided with the outer protective layer or the armor layer, after the optical cable is laid, when the midway branch requirement exists, the optical cable needs to be stripped, the operation process is very complicated, the requirement of stripping operation cannot be completed rapidly, and the operation cost is increased.
In addition, with the increase of the application scenes of the optical cable, application scenes with less high requirements on the mechanical performance of the optical cable are increasingly appeared, and under the scenes, if the conventional optical cable structure is still used, the use convenience is poor, and waste is caused by the excessive performance of the optical cable. Moreover, the cut optical fibers after the splitting of the branches are often not used any more, which also results in a certain degree of waste of the optical fibers.
Disclosure of Invention
Aiming at one or more of the defects or improvement demands of the prior art, the invention provides a tight-buffered optical unit, a special optical cable comprising the tight-buffered optical unit and a preparation method of the tight-buffered optical unit and the special optical cable, which can effectively reduce the dead weight of a multi-core optical cable, improve the current situations of difficult midway branching, large long-distance laying difficulty and high cost of the traditional optical cable, and reduce the application cost of the optical cable.
To achieve the above object, in one aspect of the present invention, there is provided a tight-buffered optical unit including an optical fiber at a center; the periphery of the optical fiber is sequentially coated with a buffer layer, a reinforcing layer and a tight sleeve layer from inside to outside;
the reinforcing layer is formed by cladding a high-strength nonmetallic fiber material, the cladding thickness is 0.1+/-0.05 mm, the elastic modulus is not lower than 90Gpa, and the linear density is between 50dtex and 1000 dtex;
the tight sleeve layer is formed by extrusion molding of a thermotropic LCP material, the extrusion temperature of the thermotropic LCP material is 280-320 ℃, the molding thickness of the tight sleeve layer is 0.08-0.15 mm, and the outer diameter of the molded tight sleeve light unit is 0.3-0.6 mm.
As a further improvement of the invention, the optical fiber is a single-mode bending-resistant optical fiber, the outer diameter of the optical fiber is 200+/-5 mu m, the attenuation of 1310nm wavelength is less than or equal to 0.35dB/km, and the attenuation of 1550nm wavelength is less than or equal to 0.20dB/km.
As a further improvement of the invention, the buffer layer is obtained by longitudinally wrapping or wrapping a PTFE film; and/or the reinforcing layer is formed by cladding aramid fiber.
In another aspect of the present invention, there is also provided a special optical cable woven into a cable based on tight-buffered optical units, the special optical cable being woven into a cable by a plurality of woven units, a middle portion of which is formed with a middle cavity extending in a length direction of the optical cable;
each braiding unit comprises a tight sleeve light unit with a certain length; and the braiding coverage rate of the braiding units in each region of the optical cable is not more than 50%.
As a further improvement of the invention, a central member is provided in the central cavity in the longitudinal direction, so that a plurality of the tight-buffered light units are woven into a cable around the central member.
As a further improvement of the invention, the central member is a central reinforcing member; alternatively, the center piece is a thin-diameter optical cable.
As a further improvement of the present invention, the center member is a center reinforcing member made of KFRP material, and the tensile strength of the KFRP material is not less than 1700Mpa, and the minimum bending diameter is not more than 30 times the diameter of the center reinforcing member itself.
As a further improvement of the present invention, an outer coating layer is provided on the outer jacket layer of the tight-buffered light unit, and the outer diameter of the center piece is calculated by the following formula:
in the method, in the process of the invention,dis the outer diameter of the tight-sleeved light unit;athe thickness of the outer coating is the thickness of the outer periphery of the tight-sleeved light unit;Nis the number of units of the tight-buffered light unit.
As a further development of the invention, at least one braiding unit is formed by connecting the tight-buffered optical unit and the non-optical unit without optical fibers by means of end-splicing.
As a further development of the invention, the connection between the non-light unit and the tight-buffered light unit is achieved by connecting the non-light unit to the end of the stiffening layer in the tight-buffered light unit;
or alternatively
The non-optical unit is obtained by cutting off the optical fiber in the preparation process of the tight-buffered optical unit, stopping feeding the optical fiber, and then continuing to mold the reinforcing layer and/or the tight-buffered layer.
As a further development of the invention, the equivalent outer diameter of the non-light unit differs from the outer diameter of the tight-fitting light unit by no more than 20% of the outer diameter of the tight-fitting light unit.
In another aspect of the invention, a method for preparing a tight-buffered light unit is provided, for preparing the tight-buffered light unit; the preparation method comprises the following steps:
(1.1) selecting a proper optical fiber, and feeding the optical fiber at a paying-off tension of 0.5N-1.2N;
(1.2) coating the outer periphery of the fed optical fiber with a buffer layer;
(1.3) carrying out cladding molding of the reinforcing layer on the periphery of the buffer layer by using high-strength non-metal fibers, so that the elastic modulus of the reinforcing layer is not lower than 90Gpa, and the linear density is between 50dtex and 1000 dtex;
(1.4) extruding and molding a tight sleeve layer with the thickness of 0.08-0.15 mm on the outer Zhou Tongguo thermotropic LCP material of the over-molded reinforcing layer to form a tight sleeve light unit, and controlling the wire winding tension of the tight sleeve light unit to be 1-2N.
In another aspect, the present invention also provides a method for preparing a special optical cable, for preparing the special optical cable braided into a cable based on tight-buffered optical units, the preparation method comprising the following steps of
(1) Preparing a plurality of tight-sleeved light units for standby according to the preparation method of the tight-sleeved light units;
(2) Setting a braiding machine to braid a plurality of tight-sleeved light units into a cable;
in the weaving and cabling process, each tight sleeve light unit is kept in a straight state, the paying-off tension of each tight sleeve light unit is controlled within the range of 0-10N, and the weaving coverage rate of each area after cabling is not more than 50%.
As a further development of the invention, in process (1), a shaping process with non-light units is carried out during the preparation of at least part of the tight-fitting light units, the shaping process being as follows:
cutting off the optical fiber and stopping feeding the optical fiber after the tight-buffered optical unit is prepared to a certain length, stopping forming the reinforcing layer, and continuing forming the tight-buffered layer to a specified length;
or alternatively
Cutting off the optical fiber and stopping feeding the optical fiber after the tight-buffered optical unit is prepared to a certain length, stopping forming the tight-buffered layer, and continuing forming the reinforcing layer until the reinforcing layer is formed to a specified length;
or alternatively
After the tight-buffered optical unit is prepared to a certain length, the optical fiber is cut off and the feeding of the optical fiber is stopped, and thereafter, the formation of the reinforcing layer and the tight-buffered layer is continued until the prescribed length.
As a further improvement of the present invention, in the process (2), a succession process of partly covering the non-light units at the ends of the light units is also performed:
when a plurality of tight-sleeve light units are produced to a first designated length in a braiding mode, stopping braiding, replacing a part of the fed tight-sleeve light units with non-light units, and connecting the non-light units with the end parts of the corresponding tight-sleeve light units; and continuing the braiding operation of the optical cable to the second designated length, stopping the braiding operation, and repeating the replacement and connection operation of the non-optical units until the production of the special optical cable is finally completed.
The above-mentioned improved technical features can be combined with each other as long as they do not collide with each other.
In general, compared with the prior art, the above technical solution conceived by the present invention has the following beneficial effects:
(1) The tight-sleeved light unit comprises the optical fiber, the buffer layer, the reinforcing layer and the tight-sleeved layer which are sequentially arranged from inside to outside, and the tensile capacity of the tight-sleeved light unit can be effectively ensured by selecting and correspondingly arranging the materials of the reinforcing layer and the tight-sleeved layer, so that the knitting use and the independent use reliability of the tight-sleeved light unit are improved.
(2) The special optical cable based on the tight-buffered optical units is obtained by braiding the tight-buffered optical units, the cable can be rapidly formed in a braiding mode by the optimal arrangement of the tight-buffered optical units and the optimal shaping mode of the tight-buffered optical units, the self weight of the optical cable and the difficulty in the use of optical cable branching can be effectively reduced, the braiding surplus length with a certain length can be generated after the optical cable is shaped, the optical cable can be provided with larger stretching buffer when being pulled, the situation that the optical cable is stressed when being pulled is avoided, the tensile strength of the optical cable is further improved, and the service performance of the optical cable is improved.
(3) According to the special optical cable woven into the cable based on the tight-buffered optical unit, the tight-buffered optical unit is woven on the periphery of the central part formed by the central reinforcing part or the small-diameter optical cable, so that the forming roundness of the optical cable is higher, the tensile capacity of the optical cable is further enhanced, the long-distance laying capacity of the optical cable is improved, and the application range of the optical cable is enlarged; meanwhile, through the connection arrangement of the plurality of non-optical units at the end parts of the tight sleeve optical units, the dead weight of the optical cable can be further reduced, so that the optical cable can be rapidly branched at the corresponding length position, and the waste of optical fibers caused by optical fiber branching in the traditional optical cable is effectively avoided.
(4) According to the special optical cable woven based on the tight-buffered optical unit, the butt joint mode and the size specification between the non-optical unit and the tight-buffered optical unit are preferably designed, so that the preparation process of the special optical cable can be further simplified, the preparation efficiency of the special optical cable is improved, and the preparation and application cost of the special optical cable is reduced.
(5) The preparation method of the tight-buffered optical unit and the preparation method of the special optical cable have the advantages of simple steps and convenient control, can rapidly realize the preparation of the tight-buffered optical unit and the braiding and forming of the corresponding special optical cable, simplify the forming process of the optical cable, improve the efficiency and the forming quality of the optical cable, and reduce the application cost of the special optical cable.
(6) The tight-buffered optical unit and the special optical cable woven based on the tight-buffered optical unit are simple in structure and convenient to prepare, can effectively simplify the forming process of the optical cable on the basis of fully guaranteeing the tensile strength of the tight-buffered optical unit and the special optical cable, reduce the unit weight of the optical cable, overcome the problems of difficult midway branching, large long-distance laying difficulty and high cost of the traditional optical cable, effectively guarantee the service performance of the special optical cable, reduce the waste of optical fiber materials in the use process of the special optical cable, reduce the application cost of the optical cable and have good practical value.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic cross-sectional view of a tight-fitting light unit according to an embodiment of the present invention;
FIG. 2 is a schematic cross-sectional view of an optical fiber subunit according to an embodiment of the invention;
FIG. 3 is a schematic diagram of an embodiment of the present invention in which the optical fiber subunits are connected to the ends of the non-optical units;
like reference numerals denote like technical features throughout the drawings, in particular:
1. tightly sleeving the light unit; 2. a center piece; 3. a non-light unit;
101. an optical fiber; 102. a buffer layer; 103. a reinforcing layer; 104. and (5) tightly sleeving the layers.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention. In addition, the technical features of the embodiments of the present invention described below may be combined with each other as long as they do not collide with each other.
In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the device or element being referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present invention.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In the description of the present invention, the meaning of "plurality" means at least two, for example, two, three, etc., unless specifically defined otherwise.
In the present invention, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; either directly or indirectly, through intermediaries, or both, may be in communication with each other or in interaction with each other, unless expressly defined otherwise. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.
In the present invention, unless expressly stated or limited otherwise, a first feature "up" or "down" a second feature may be the first and second features in direct contact, or the first and second features in indirect contact via an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.
Examples:
referring to fig. 1 to 2, the special optical cable in the preferred embodiment of the present invention is woven based on a plurality of tight-buffered optical units 1, so as to form a long-axis cable structure with a hollow interior.
Specifically, the tight-buffered optical unit 1 in the preferred embodiment includes an optical fiber 101 at the center and a buffer layer 102, a reinforcing layer 103, and a tight-buffered layer 104 sequentially disposed from inside to outside of the optical fiber 101, as shown in fig. 2.
Wherein the optical fiber 101 in the preferred embodiment is preferably a single mode bending resistant optical fiber, and the outer diameter dimension thereof is preferably 200+ -5 μm, and the 1310nm wavelength attenuation is less than or equal to 0.35dB/km, and the 1550nm wavelength attenuation is less than or equal to 0.20dB/km.
Next, the buffer layer 102 on the outer periphery of the optical fiber 101 in the preferred embodiment is preferably formed by wrapping a PTFE film in a longitudinal wrapping or winding manner by a molding die, and the thickness of the wrapping is preferably 0.15±0.05mm for buffering the pressing force between the tight-buffered light unit 1 and the center member 2 and between the adjacent tight-buffered light units 1 during the braiding of the subsequent tight-buffered light unit 1. In the actual cladding operation, the width of the buffer layer 102 for cladding is preferably 1 to 2mm larger than the circumference of the optical fiber.
Meanwhile, the reinforcing layer 103 in the preferred embodiment is wrapped around the periphery of the buffer layer 102 along the circumferential direction, and is preferably formed by wrapping high-strength non-metal fibers with smaller linear density, so as to further improve the tensile property of the tight-buffered optical unit 1 and provide conditions for the connection between the subsequent tight-buffered optical unit 1 and the non-optical unit 3, which will be described in detail in the following description, and will not be repeated here.
In practical arrangement, the thickness of the wrapping of the reinforcing layer 103 is preferably 0.1±0.05mm, the elastic modulus is preferably not lower than 90Gpa, and the linear density is between 50dtex and 1000 dtex.
Further preferably, the reinforcement layer 103 in the preferred embodiment is an aramid fiber that is preferably evenly distributed around the periphery of the buffer layer 102 through the splitter plate during the cladding arrangement.
Further, the tight-fitting layer 104 in the preferred embodiment is preferably formed on the outer periphery of the reinforcing layer 103 by extrusion molding from an LCP material (Liquid Crystal Polymer, liquid crystal polymer material/liquid crystal polymer material).
Compared with the tensile strength of the conventional tight-buffered material between 9 and 50MPa, the tensile strength of the LCP material selected in the preferred embodiment can reach more than 800MPa, which is more than tens of times of the tensile strength of the conventional tight-buffered material, and the tensile strength of the tight-buffered optical unit 1 and the related special optical cable can be greatly improved.
In practice, to ensure that the LCP material can be shaped in an extrusion-molded manner, a thermotropic LCP material is preferably used and its temperature characteristic parameters are defined, specifically, the optimal extrusion temperature of the LCP material in the preferred embodiment is between 280 ℃ and 320 ℃.
In addition, in order to ensure that the formed tight-sleeve layer 104 meets the design requirements of consistency of tensile strength and outer diameter, the formed thickness of the tight-sleeve layer 104 in the preferred embodiment is preferably between 0.08 mm and 0.15mm, and preferably is 0.1mm. Compared with the conventional tight-buffered optical fiber with the tight-buffered layer thickness of not less than 0.3mm, the tight-buffered layer 104 of the tight-buffered optical unit 1 in the preferred embodiment has smaller thickness, so that the tight-buffered optical unit 1 has smaller size and lighter weight, and can meet the requirement of braiding cables.
By arranging the functional layer consisting of the buffer layer 102 and the reinforcing layer 103 between the tight sleeve layer 104 and the optical fiber 101, the optical fiber 101 can have a certain excess length, so that the buffer space of the optical fiber 101 is ensured when the tight sleeve light unit 1 is subjected to tensile force, and the optical fiber 101 in the tight sleeve light unit 1 is not stressed.
According to practical verification, for the tight-buffered optical unit 1 without the buffer layer 102 and the stiffening layer 103, the excess fiber length in the tight-buffered layer 104 is then 0; by the above arrangement of the buffer layer 102 and the reinforcing layer 103, the optical fiber 101 can have a residual length of 0 to 1%.
In more detail, in order to further improve the abrasion resistance of the tight-buffered optical unit 1 and prolong the service life of the special optical cable, an outer coating layer is coated and arranged on the periphery of the tight-buffered layer 104 of the tight-buffered optical unit 1, and is preferably formed by coating an acrylic resin material; in order to avoid coating stripping and to exceed the outer diameter design of the cable, the coating thickness of the outer coating in the preferred embodiment is preferably 5-30 μm.
In addition, in order to facilitate discrimination and identification between the respective tight-fitting light units 1, it is further preferable to provide different colored layers or to make different marks outside the outer coating of the respective tight-fitting light units 1.
For the tight-buffered light unit 1 which is completely arranged, the outer diameter of the tight-buffered light unit is preferably 0.3-0.6 mm; the tight-buffered optical unit 1 in the preferred embodiment has a smaller outer diameter than a conventional tight-buffered optical fiber (typically 0.9mm in outer diameter), which is a compromise between the strength, outer diameter and weight of the tight-buffered optical unit 1, and is a result of the design of the outer diameter of the cable after subsequent cabling.
Further, there is provided in a preferred embodiment a special optical cable based on the aforesaid tight-buffered light units 1, preferably cabled in a braided manner by means of a plurality of the aforesaid tight-buffered light units 1, and forming a longitudinally extending central cavity in the central part of the special optical cable.
In practice, it is preferable to provide the central member 2 in the aforementioned tubular cavity, that is, to form a braid by braiding a plurality of tight-buffered light units 1 around the outer circumference of the central member 2 to complete cabling of the optical cable. Preferably, the outer diameter of the special optical cable woven into the cable is preferably between 1.3 and 5.0 mm.
In more detail, the central member 2 in the preferred embodiment may be a central reinforcing member or a small diameter optical cable inserted through the middle of a special optical cable. In a specific arrangement, the feeding of the center piece 2 may be performed simultaneously with the feeding of the plurality of tight-fitting light units 1, so that the tight-fitting light units 1 are woven on the outer periphery of the center piece 2.
In practical design, the center piece 2 is provided with an outer diameterDPreferably by the following formula:
in the method, in the process of the invention,dis the outer diameter of the tight-sleeved light unit 1;athe thickness of the outer coating layer is the thickness of the outer periphery of the tight-sleeved light unit 1;Nis the number of units of the tight-fitting light unit 1. By this arrangement, the gap between the tight fitting light unit 1 and the central member 2 can be minimized, resulting in a more compact and round whole cable.
In the preferred embodiment shown in fig. 1, the central member 2 is a central reinforcing member for increasing the tensile strength of a special optical cable, and is preferably made of a non-metallic KFRP material having a relatively soft texture, having a smaller pressing force against the surrounding tight fitting light unit 1 when bent, and improving the bending performance of the optical cable, so that the optical cable can be arranged with a smaller bending radius.
More specifically, considering that the tight-buffered optical unit 1 has a small cable diameter and needs long-length and long-distance laying construction in the following, the KFRP material in the preferred embodiment needs to meet the special stretching and bending requirements of the special optical cable, and the bending and bending resistance needs to be further ensured, so that the tensile strength is preferably not less than 1700Mpa, and the minimum bending diameter is not more than 30 times of the diameter of the central reinforcing member itself.
Further, in order to avoid the risk of fiber breakage and large attenuation at the crossing overlapping part during the braiding process of the tight-buffered light units 1, in a preferred embodiment, the braiding coverage of the multiple tight-buffered light units 1 at each position within the length interval of the optical cable is not more than 50%. In a preferred embodiment, the control of the braiding coverage of the tight-fitting light unit 1 is preferably performed by adjusting the braiding pitch, which is further calculated by the following formula:
in the method, in the process of the invention,Pfor braid coverage,%;pis a coverage coefficient;mis the number of knitting units;dis the outer diameter of the braiding unit;D' is the braid outer diameter measurement; l is the braiding pitch.
Meanwhile, in order to ensure that the damage to the optical fiber 101 in the tight-buffered optical unit 1 is as small as possible in the braiding process of the special optical cable, the tensile strength of the tight-buffered optical unit 1 is preferably designed, the smooth paying-off and no jitter should be ensured in the braiding process, and the paying-off tension is ensured to be as small as possible under the condition that the unit is straightened, and in a preferred embodiment, the paying-off tension is preferably 0N-10N.
Accordingly, if the weaving process of the tight-fitting optical unit 1 is performed on the outer circumference of the center member 2, it is necessary to ensure that the paying-off tension of the center member 2 is as large as possible, which is contrary to the current situation that the paying-off tension of the centrally located element in the conventional weaving process is as small as possible, which is also a result of the special design based on the special structure of the special optical cable in the preferred embodiment, and the quality of the weaving formation of the special optical cable can be better ensured.
It will be appreciated, of course, that when the central member 2 is a thin diameter cable, its paying-off tension should ensure that the light units in its own structure are unaffected.
It is further preferred that, for situations where there is often a mid-way branching of the cable during the actual laying process, and where the remaining optical fibers of the cable are wasted, the length of at least part of the tight-buffered light unit 1 used for braiding in the preferred embodiment does not correspond to the full length of the special cable.
More specifically, at least part of the braiding units for braiding into a cable is a composite braiding unit in which a tight-buffered optical unit 1 is combined with a non-optical unit 3 not including an optical fiber 101, the composite braiding unit including a length of the tight-buffered optical unit 1 and the non-optical unit 3 connected to one end thereof, the length of the composite braiding unit corresponding to the length of the special optical cable after braiding into a cable.
It will be appreciated that, in view of the fact that the braiding units are arranged in a braided fashion, which does not extend entirely along the axial direction of the cable, the length of the braiding units is greater than the length of the specialty cable when actually arranged.
The butt joint of the non-optical units 3 at the end parts of the tight-buffered optical units 1 and the corresponding braiding operation of the braiding units are utilized, so that one part of the special optical cable is braided by the tight-buffered optical units 1, and the other part of the special optical cable is braided by the tight-buffered optical units 1 and the non-optical units 3.
In more detail, the non-light unit 3 in the preferred embodiment is preferably made of high strength non-metal fibers, which are further preferably the same material as used for the reinforcing layer 103. For example, in a preferred embodiment, the non-light unit 3 is made of an aramid fiber material. Further, the knitting coverage of each portion is preferably not more than 50% after the tight-fitting light unit 1 is replaced with the non-light unit 3.
Further, for the connection of the non-light unit 3 and the end of the tight-buffered light unit 1, the preferred embodiment is preferably accomplished by means of compression welding butt joint by a welder or bonding by glue; when the tensile strength of the braiding unit is high, it may be further preferable to butt-joint in a knotted manner.
In more detail, when the butt joint operation is actually performed, the difference between the equivalent outer diameter of the non-optical unit 3 and the outer diameter of the tight-buffered optical unit 1 is preferably not more than 20% of the outer diameter of the tight-buffered optical unit 1, so that, on the one hand, the non-optical unit 3 adopts aramid fiber, the outside of which is not protected, and in consideration of the risk that a part of the aramid fiber filaments in the non-optical unit 3 may break during knitting and in the subsequent use, the reinforcing layer 103 in the tight-buffered optical unit 1 does not present such a problem because of the protection of the tight-buffered layer 104. Therefore, in order to effectively ensure the strength of the non-light unit 3, the equivalent outer diameter of the non-light unit 3 should not be less than 80% of the outer diameter of the tight-buffered light unit 1; on the other hand, according to theoretical calculation, in a typical product, the equivalent thickness of the reinforcing layer 103 is about 25% of the outer diameter of the tight-buffered optical unit 1, and the outer diameter of the butt joint part is 1.05 times of the outer diameter of the tight-buffered optical unit 1 and 1.45 times of the outer diameter of the tight-buffered optical unit 1, and the aramid fiber is added as a yarn formed by filaments, so that the yarn can be extruded and deformed, and the outer diameter of the whole optical cable is not greatly influenced, thereby effectively ensuring the roundness of the optical cable after the optical cable is woven.
Of course, other docking methods than the above described one may be preferable according to actual needs as long as the end connection between the tight-fitting light unit 1 and the non-light unit 3 can be completed. For example, in a particularly preferred embodiment, the connection between the two is made in a butt-free manner.
In a preferred embodiment, the specific implementation of the above-mentioned docking-free manner is as follows:
in the process of manufacturing the tight-buffered optical unit 1, after it is manufactured to a certain length, the optical fiber 101 is cut off and the feeding of the optical fiber 101 is stopped, and the molding of the reinforcing layer 103 is stopped, after which the tight-buffered layer 104 is continuously molded to a prescribed length (in this case, the tight-buffered layer 104 does not have the optical fiber 101, the buffer layer 102 and the reinforcing layer 103, which exist only as the non-optical unit 3); alternatively, after the tight-buffered optical unit 1 is prepared to a predetermined length, the optical fiber 101 is cut off, the feeding of the optical fiber 101 is stopped, the extrusion of the tight-buffered layer 104 is stopped, and then the molding of the reinforcing layer 103 is continued until the predetermined length is reached. Of course, the shaping of the reinforcing layer 103 and the extrusion of the tight-buffered layer 104 may be continued after cutting the optical fiber 101, to form a non-optical unit composed of the reinforcing layer 103 and the tight-buffered layer 104, according to the actual installation requirements.
Preferably, in the actual setting, in the special optical cable woven into the cable, the weaving units provided with the non-optical units 3 preferably account for 40% -80% of the total number of the weaving units, for example, for the preferred embodiment shown in fig. 1, the number of the weaving units is 8, and the number of the weaving units provided with the non-optical units 3 is preferably 4% -6.
More preferably, at the time of actual arrangement, at least one braided unit not provided with the non-light unit 3 exists in the special optical cable braided into a cable.
As another aspect of the preferred embodiment of the present invention, there is correspondingly provided a manufacturing method for preparing the aforementioned special optical cable, which preferably includes the following processes:
(1) Preparing the tight-fitting light unit 1;
specifically, the preparation process of the tight-fitting light unit 1 in the preferred embodiment specifically includes the following processes:
(1.1) selecting an optical fiber 101 with a proper size for feeding, and controlling the paying-off tension of the optical fiber 101 to be between 0.5N and 1.2N;
preferably, the actual selected fiber 101 is a single mode bending resistant fiber.
(1.2) a buffer layer 102 of 0.15.+ -. 0.05mm thickness is provided around the outer periphery of the fed optical fiber 101 by wrapping or wrapping with a PTFE film;
(1.3) carrying out cladding molding of the reinforcing layer 103 by high-strength nonmetallic fibers on the periphery of the buffer layer 102, and enabling the elastic modulus of the reinforcing layer 103 to be not lower than 90Gpa and the linear density to be between 50dtex and 1000 dtex;
(1.4) extruding and molding a tight sleeve layer 104 with corresponding thickness on the periphery of the reinforced layer 103 through LCP material, and controlling the wire winding tension of the tight sleeve light unit 1 to be 1N-2N, so that the optical fiber in the tight sleeve light unit has a residual length within 1 per mill, and further forming the tight sleeve light unit 1 for standby;
further, an outer coating, which in the preferred embodiment is applied by acrylic, is applied to the outer periphery of the formed gripping sheet 104.
In addition, before the tight sleeve layer 104 is formed, the thermotropic LCP material to be extruded is further preferably dried and preheated, the temperature of the material is preferably 100-150 ℃, and the material drying time is preferably 3-8 hours.
(2) Braiding the tight-sleeved light unit 1 into a cable;
when the central piece 2 is arranged in the middle of the special optical cable in actual operation, the central piece 2 and the plurality of tight-sleeved light units 1 are respectively fixed on a pay-off rack and a braiding spindle of a braiding machine, and then reasonable take-up and pay-off tension, braiding pitch and production speed are set; then, controlling the braiding machine to start up and work and starting to produce braided cables;
when the knitting is produced to a first designated length (the position where a plurality of tight-buffered light units 1 are connected with the non-light units 3), stopping the knitting, replacing the tight-buffered light units 1 on the corresponding spindles with the non-light units 3, and connecting the non-light units 3 with the end parts of the corresponding tight-buffered light units 1; thereafter, the braiding operation of the optical cable is continued to a second designated length (the position where the other part of the tight-buffered optical unit 1 is connected to the non-optical unit 3), the braiding operation is stopped, and the replacement and connection operation of the non-optical unit 3 is repeated until the production of the special optical cable is finally completed.
Obviously, for the braiding unit of the non-optical unit 3 prepared in a continuous preparation process in a certain length interval in the preparation process of the tight-buffered optical unit 1, the braiding unit can be continuously braided into a cable in the process (2) of braiding into a cable without the replacement of the tight-buffered optical unit 1 and the shutdown process of equipment until the production of the whole optical cable is completed.
In addition, in the case that the central piece 2 is not arranged in the middle of the special optical cable, the braiding process is consistent with that when the central piece 2 is arranged, but the winding tension is smaller than that when the central piece 2 is arranged.
For the braiding and cabling process in the preferred embodiment, compared with the traditional cabling process, the process is simpler, and the forming operation process of armor and an inner sheath layer is not involved; moreover, the controllability of the braiding process is strong, the process parameter adjustment is convenient and convenient, the production is very stable, the qualification rate of the product is high, the dimension of the braided cable is stable, the consistency is good, and the bending resistance and the torsion resistance of the braided cable are more excellent.
As an exemplary product embodiment of the present invention, it is preferable to provide a special optical cable whose outer diameter of the tight-buffered optical unit 1 is 0.4mm and the number of braid settings is 8; the outer diameter of the optical cable is 1.6+/-0.1 mm, and the unit weight of the optical cable is 1.5g/m.
The tight-buffered optical unit and the special optical cable woven based on the tight-buffered optical unit are simple in structure and convenient to prepare, can effectively simplify the forming process of the optical cable on the basis of fully guaranteeing the tensile strength of the tight-buffered optical unit and the special optical cable, reduce the unit weight of the optical cable, overcome the problems of difficult midway branching, large long-distance laying difficulty and high cost of the traditional optical cable, effectively guarantee the service performance of the special optical cable, reduce the waste of optical fiber materials in the use process of the special optical cable, reduce the application cost of the optical cable and have good practical value.
It will be readily appreciated by those skilled in the art that the foregoing description is merely a preferred embodiment of the invention and is not intended to limit the invention, but any modifications, equivalents, improvements or alternatives falling within the spirit and principles of the invention are intended to be included within the scope of the invention.
Claims (14)
1. A tight-buffered light unit comprising a centrally located optical fiber; the optical fiber is characterized in that a buffer layer, a reinforcing layer and a tight sleeve layer are sequentially coated on the periphery of the optical fiber from inside to outside;
the reinforcing layer is formed by cladding a high-strength nonmetallic fiber material, the cladding thickness is 0.1+/-0.05 mm, the elastic modulus is not lower than 90Gpa, and the linear density is between 50dtex and 1000 dtex;
the tight sleeve layer is formed by extrusion molding of a thermotropic LCP material, the extrusion temperature of the thermotropic LCP material is 280-320 ℃, the molding thickness of the tight sleeve layer is 0.08-0.15 mm, and the outer diameter of the molded tight sleeve light unit is 0.3-0.6 mm.
2. The tight-buffered light unit of claim 1 wherein the buffer layer is formed from a PTFE film by longitudinal wrapping or wrapping; and/or the reinforcing layer is formed by cladding aramid fiber.
3. The special optical cable is characterized by being woven by a plurality of weaving units, and a middle cavity extending along the length direction of the optical cable is formed in the special optical cable;
each of the braiding units comprises a length of the tight-fitting light unit according to claim 1 or 2; and the braiding coverage rate of the braiding units in each region of the optical cable is not more than 50%.
4. A special optical cable based on tight-buffered light units braided into a cable according to claim 3, characterized in that a central member is provided in the central cavity in the longitudinal direction, such that a plurality of tight-buffered light units are braided into a cable at the periphery of the central member.
5. The tight-buffered optical unit-based braided-cable specialty cable of claim 4, wherein said central member is a central strength member; alternatively, the center piece is a thin-diameter optical cable.
6. The special optical cable based on tight-buffered optical unit braided into a cable according to claim 5, wherein the central member is a central reinforcing member made of KFRP material, and the tensile strength of the KFRP material is not less than 1700Mpa, and the minimum bending diameter is not more than 30 times the diameter of the central reinforcing member itself.
7. The special optical cable based on the tight-buffered light unit woven into a cable according to claim 4, wherein an outer coating layer is coated on the tight-buffered layer of the tight-buffered light unit, and the outer diameter of the center piece is calculated by the following formula:
in the method, in the process of the invention,dis the outer diameter of the tight-sleeved light unit;ais a tight-fitting light unitAn outer coating thickness of the outer periphery;Nis the number of units of the tight-buffered light unit.
8. The special optical cable woven into a cable based on tight-buffered optical units as claimed in any one of claims 3 to 7, wherein at least one woven unit is formed by connecting the tight-buffered optical unit and a non-optical unit not containing optical fibers by end connection.
9. The tight-buffered optical fiber cable based on tight-buffered optical units of claim 8, wherein the connection between said non-optical units and said tight-buffered optical units is accomplished by end-connecting the non-optical units to a reinforcement layer in said tight-buffered optical units;
or alternatively
The non-optical unit is obtained by cutting off the optical fiber in the preparation process of the tight-buffered optical unit, stopping feeding the optical fiber, and then continuing to mold the reinforcing layer and/or the tight-buffered layer.
10. The tight-buffered, optical-unit-braided-cable-based specialty cable of claim 8, wherein said equivalent outer diameter of said non-optical unit differs from said tight-buffered, optical-unit outer diameter by no more than 20% of said tight-buffered, optical-unit outer diameter.
11. A method of producing a tight-fitting light unit for use in the production of a tight-fitting light unit as claimed in claim 1 or 2; the preparation method is characterized by comprising the following steps:
(1.1) selecting a proper optical fiber, and feeding the optical fiber at a paying-off tension of 0.5N-1.2N;
(1.2) coating the outer periphery of the fed optical fiber with a buffer layer;
(1.3) carrying out cladding molding of the reinforcing layer on the periphery of the buffer layer by using high-strength non-metal fibers, so that the elastic modulus of the reinforcing layer is not lower than 90Gpa, and the linear density is between 50dtex and 1000 dtex;
(1.4) extruding and molding a tight sleeve layer with the thickness of 0.08-0.15 mm on the outer Zhou Tongguo thermotropic LCP material of the over-molded reinforcing layer to form a tight sleeve light unit, and controlling the wire winding tension of the tight sleeve light unit to be 1-2N.
12. A method for preparing a special optical cable, which is used for preparing the special optical cable braided into a cable based on a tight-buffered optical unit according to any one of claims 3-10, and is characterized by comprising the following steps of
(1) The method for manufacturing tight-fitting light units according to claim 11, wherein a plurality of tight-fitting light units are prepared for standby;
(2) Setting a braiding machine to braid a plurality of tight-sleeved light units into a cable;
in the weaving and cabling process, each tight sleeve light unit is kept in a straight state, the paying-off tension of each tight sleeve light unit is controlled within the range of 0-10N, and the weaving coverage rate of each area after cabling is not more than 50%.
13. The method of manufacturing a specialty fiber optic cable of claim 12, wherein in process (1), a molding process with non-optical units is performed during the manufacture of at least a portion of the tight-buffered optical units, the molding process being as follows:
cutting off the optical fiber and stopping feeding the optical fiber after the tight-buffered optical unit is prepared to a certain length, stopping forming the reinforcing layer, and continuing forming the tight-buffered layer to a specified length;
or alternatively
Cutting off the optical fiber and stopping feeding the optical fiber after the tight-buffered optical unit is prepared to a certain length, stopping forming the tight-buffered layer, and continuing forming the reinforcing layer until the reinforcing layer is formed to a specified length;
or alternatively
After the tight-buffered optical unit is prepared to a certain length, the optical fiber is cut off and the feeding of the optical fiber is stopped, and thereafter, the formation of the reinforcing layer and the tight-buffered layer is continued until the prescribed length.
14. The method of manufacturing a specialty fiber cable according to claim 12 or 13, wherein in process (2), a splicing process is further performed with a portion of the optical unit end non-optical unit being tightly sleeved:
when a plurality of tight-sleeve light units are produced to a first designated length in a braiding mode, stopping braiding, replacing a part of the fed tight-sleeve light units with non-light units, and connecting the non-light units with the end parts of the corresponding tight-sleeve light units; and continuing the braiding operation of the optical cable to the second designated length, stopping the braiding operation, and repeating the replacement and connection operation of the non-optical units until the production of the special optical cable is finally completed.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311430262.7A CN117492154A (en) | 2023-10-31 | 2023-10-31 | Tight sleeve optical unit, special optical cable comprising same and preparation methods of tight sleeve optical unit and special optical cable |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311430262.7A CN117492154A (en) | 2023-10-31 | 2023-10-31 | Tight sleeve optical unit, special optical cable comprising same and preparation methods of tight sleeve optical unit and special optical cable |
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| CN117492154A true CN117492154A (en) | 2024-02-02 |
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| CN202311430262.7A Pending CN117492154A (en) | 2023-10-31 | 2023-10-31 | Tight sleeve optical unit, special optical cable comprising same and preparation methods of tight sleeve optical unit and special optical cable |
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| CN (1) | CN117492154A (en) |
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- 2023-10-31 CN CN202311430262.7A patent/CN117492154A/en active Pending
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