CN1206662C - 用于缓冲电信电缆中传输元的柔韧热塑性聚烯烃高弹性体 - Google Patents
用于缓冲电信电缆中传输元的柔韧热塑性聚烯烃高弹性体 Download PDFInfo
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Abstract
本发明公开了一种电信电缆元,该电信电缆元具有传输元,传输元被置于由热塑性聚烯烃高弹性缓冲材料制成的缓冲管内。热塑性聚烯烃高弹性材料的室温弹性模量在约500Mpa以下,-40℃下的弹性模量在约1500MPa以下。优选地,形成缓冲管的热塑性聚烯烃高弹性材料的断裂伸长率低于约500%,熔体流动指数高于约3。
Description
技术领域
本发明涉及电信电缆,尤其是涉及具有由热塑性聚烯烃高弹性体缓冲的光纤的电信电缆。
背景技术
在具有传输元的电信电缆,如涂有紫外光防护涂层的光纤中,传输元一般独立或整体地被缓冲材料保护。传输元和缓冲材料之间的关系通常被描述为“紧密”、“近于紧密”或“松散”,例如,一个被“紧密”缓冲的光纤,其涂层材料直接涂于光纤。被“近于紧密”缓冲的光纤具有一个中空的缓冲膜,通常为一个内径(直径)稍大于(至多约0.4mm)光纤外径或内含的复合(多元)光纤近似外径的壳体,例如,被“近于紧密”缓冲的光纤通常由一个或多个由护套或韧性材料的缓冲件包裹的光纤组成。韧性缓冲件的壁厚约为0.2mm,内径(半径)小于0.3mm但大于内含光纤束的内径。更具体地说,例如,一个4纤维韧性缓冲管的外径(OD)为1.0mm,内径(ID)为0.6mm;一个6纤维韧性缓冲件的OD为1.15mm,ID为0.75mm;一个12纤维的韧性缓冲件的OD为1.4mm,ID为1.0mm。使用如此紧密结合的缓冲件,有可能设计整体OD较小、每单元长度重量较轻的电缆。这些缓冲件还容许电缆在较小的直径内包含较高的纤维密度。
在被“松散”缓冲的光纤电缆内,缓冲管的内径远大于(约在0.4mm以上)光纤的外径或光纤束的近似外径。本领域对松散缓冲光纤电缆的设计非常清楚。
对于紧密和近于紧密缓冲的应用,要求弹性模量低,以保证在不损害内包纤维的情况下,缓冲件容易接近及便于控制。紧密和近于紧密缓冲膜与所覆纤维的接触较紧密。为了使接触较好分布于所覆纤维,模量需处于特定范围内。
用于制造缓冲电信电缆光纤缓冲管的典型缓冲材料包括增塑聚氯乙烯(PVC)、聚对苯二甲酸丁二醇酯(PBT)、聚碳酸酯(PC)和一些聚烯烃。用于缓冲光纤时,上述提到的材料有利有弊。例如,某些材料如PC和PBT的价格较高,某些材料如PVC,不能在电信电缆可能的使用温度范围内提供可接受的弹性模量,为了克服PVC的一些问题,在一些设计中使用增塑PVC。但是增塑PVC在低温下仍可能显示明显提高的模量,而且,增塑PVC的另一缺点还表现为PVC内的增塑剂可能被置于带有光纤的缓冲管内的触变性防水胶浸出。增塑剂的浸出引起缓冲件模量和刚性的提高以及内包纤维性能的降低,这种浸出在聚烯烃和多元醇基胶体中最为普遍。为降低增塑剂的浸出,必须使用含抗迁移增塑剂和兼容防水胶如硅氧烷胶的特定规格的增塑PVC,但是,硅氧烷胶的成本远高于多元醇胶或聚烯烃胶。
对于浸出问题的解决方法不仅花费高,而且并不能完全消除该问题,即使使用这样的解决办法,增塑剂的迁移或析出仍然可通过光纤涂层和缓冲膜之间的相互作用发生。
发明内容
相应地,本发明的目标之一是提供一种用于缓冲具有在较宽温度范围内可使用的弹性模量的电信电缆元的韧性缓冲材料。
本发明的另一目标是提供一种用于缓冲与低成本、触变性、防水性胶体兼容的电信电缆元的缓冲材料。
本发明的再一目标是提供一种具有由缓冲管缓冲的传送元的电信电缆元,该缓冲管不需特殊工具即可容易地与传送元剥离。
进一步的目标可通过本发明的缓冲电信电缆元实现(至少部分实现),该电信电缆元是热塑性聚烯烃高弹性缓冲材料形成的管体及置于管内的传送元。缓冲材料在室温下的弹性模量在约500MPa以下,在-40℃下的弹性模量在约1500MPa以下。传送元可以是光纤、光纤束或光纤带,传送元可以紧密、近于紧密或松散的构型置于缓冲管内。
通过阅读下列的详细叙述,并结合所附的示意图和权利要求,本发明的其它目标和优势将明显呈现出来。
附图说明
为更充分地理解本发明的性质和目标,需参考下列相关附图的详细叙述。其中:
图1为本发明中紧密缓冲电信电缆元的截面图;
图2A和图2B为本发明中近于紧密缓冲和松散缓冲电信电缆元的截面图;
图3为含有多重传输元的紧密缓冲电信电缆元的另一实例的截面图;
图4为近于紧密缓冲电信电缆元的截面图;
图5为具有带状排列多元传输元的近于紧密缓冲电信电缆元的截面图;
图6为各种用于制造缓冲元材料的热膨胀系数比较图。
具体实施方式
图1示出了由传输元12,如有涂层的光纤组成的电信电缆元10和保护性缓冲管14。在图1示出的实例中,光纤12以紧密构型置于缓冲管14内,形成紧密缓冲光纤,即缓冲管14的内径基本上与有涂层的光纤12的外径相同。图2A和图2B示出了相对于缓冲管14为近于紧密或松散构型的电信电缆元10。在近于紧密构型中,缓冲管14的内径A大于有涂层的光纤12的外径B(通常为250mm左右),但二者差值不超过0.3mm。在松散构型中,内径A与外径B的差值通常在0.3mm以上。内径A与光纤外径B之间较大判别可允许更大的超长度纤维置于缓冲管内。
图3示出了由缓冲管14以紧密构型环绕的一束(多元)光纤12。作为比较,图4示出了以近于紧密构型置于缓冲管14内的相同光纤束。图5示出了置于缓冲管14内排列成光纤带16的光纤束。对于熟悉本领域者来说,这些仅仅是电信电缆元10的各种构型的一些示例。
根据本发明,用于缓冲传送元或光纤元12的缓冲管14由热塑性聚烯烃高弹性体制成,该高弹性体在室温下的弹性模量在约500MPa以下,在低温(-40℃)下的弹性模量在约1500MPa以下。以ASTM D-1238中的方法、在条件L(230℃,2.16kg)下测定,缓冲材料的熔体流动指数最好高于约3。其中一种具有上述物理特性的热塑性聚烯烃高弹性体为丙烯和乙烯的共聚物,且该缓冲材料中共聚单体乙烯的重量百分数最好在10%以上。另一种具有上述物理特性的热塑性聚烯烃高弹性材料为含丙烯和乙烯的三元共聚物。
电信电缆元10中的缓冲管14也可以由超低密度聚丙烯或乙烯和辛烯的共聚物制成,只要这些材料在室温下的弹性模量在约500MPa以下,在低温(-40℃)下的弹性模量在约1500MPa以下。以ASTM D-1238中的方法、在条件E(190℃,2.16kg)下测定,这些材料的熔体流动指数最好高于约3。当使用乙烯和辛烯的共聚物制造缓冲管时,辛烯在共聚物中所占的重量百分数最好应高于10%。
为控制物理性质如热膨胀系数、弹性模量、断裂伸长率或阻燃性,用于形成电信电缆元10中缓冲管14的热塑性聚烯烃高弹性材料也可含有有机或无机填料,如滑石、碳酸钙、碳黑、氢化铝、氢氧化镁或其它一些阻燃剂。例如,向本发明的聚烯烃缓冲材料中加入碳酸钙,将会降低断裂伸长率。另外,缓冲材料可含有化学添加剂如紫外辐射稳定剂或热稳定剂、增塑剂、或着色剂,以改进或增强电信电缆元10中缓冲管14的性质。
优选地,形成缓冲管14的热塑性聚烯烃高弹性材料室温下应具有低断裂伸长率(<500%)。若弹性模量和断裂伸长率足够低,则紧密(图1)或近于紧密(图2)缓冲管或膜14可容易地去除,而不需特殊工具,且不损坏置于其中的光纤,例如,缓冲管14可被夹紧变形或部分切割,然后撕开直至其折断而被去除。为使该去除过程在不损害光纤12的情况下有效实施,聚烯烃材料须有低断裂伸长率和弹性模量。如果弹性模量太高,则必须使用高压夹断或分离缓冲管14,而这一过程具有引起覆盖层与光纤12剥离的危险,而且,如果缓冲管14的断裂伸长率太高,则光纤12在去除过程中可能因拉紧而损坏。通常情况下,若缓冲材料室温下的弹性模量低于500MPa,室温下的致断拉伸低于500%,最好低于300%,则去除过程非常容易进行。
对于先有技术各种增塑PVC缓冲管和根据本发明制造的聚烯烃高弹性缓冲管,试验了温度对模量的影响。分别在室温(20-25℃)和低温(-40℃)下测定温度对缓冲材料模量的影响。根据测试结果,所有增塑PVC材料室温下的模量均小于约100MPa,而不同材料低温下的模量处于1750MPa至2600MPa之间。根据测试结果,低温模量与室温模量的比值介于40和110之间,说明增塑PVC的模量随温度的变化明显。增塑PVC材料的高模量比和高低温模量也说明,这种材料将通常表现为弯曲性能低、与光纤的接触力大、缓冲管可能变脆。因此,测试结果也说明增塑PVC材料可能表现出明显的应变硬化,从而导致去除缓冲管所需力的提高。
与所测试的各种增塑PVC基缓冲管相反,所有测试的聚烯烃高弹性缓冲管的室温模量均低于约200MPa,而不同材料的低温模量处于350MPa和1200Mpa之间。根据测试结果,低温模量与室温模量之比介于10至15之间,说明与增塑PVC相比,聚烯烃高弹性缓冲管的模量随温度的变化不明显。
对先有技术各种增塑PVC材料及根据本发明制造的热塑性聚烯烃高弹性体缓冲管的热膨胀系数(CTE)进行了测试。如图6所示,热塑性聚烯烃高弹性体的CTE由-40℃下的50×106/℃近于线性地变化至85℃下的200×106/℃。增塑PVC材料的CTE由-40℃的100变化至85℃下的400以上。所测试热塑性聚烯烃高弹性材料的CTE随温度的变化明显低于所测试的增塑PVC材料。而且,值得注意的是,增塑PVC的CTE随温度的变化不是线性的,对于可在较宽温度范围内使用的电信电缆元的设计,CTE的线性变化是所希望的。
本发明中用于形成电信电缆元10的缓冲管14的热塑性聚烯烃高弹性材料,与低成本、触变性的防水胶的兼容性好于增塑PVC。本发明中用于形成电信电缆元10的缓冲管14的热塑性聚烯烃高弹性材料,可与价格不高且易得的多元醇基、触变性防水胶以及某些聚烯烃基胶兼容。在聚烯烃基胶与电信电缆元10一起使用的情况下,防水胶与缓冲材料之间的相互作用不引起弹性模量的变化,而在先有技术具有增塑PVC基缓冲结构的电信元中已观察到这一变化。
正如上面所提到的,PVC缓冲管增塑剂的迁移可引起许多问题,如剥离光纤的紫外防护涂层所需力的降低。剥离力是有涂层光纤耐久性的量度,剥离力的降低说明涂层光纤机械强度可靠性的下降,例如,当PVC缓冲管使用硅胶防水胶时,由光纤剥离紫外防护涂层所需的力降低。这一现象也较轻程度地存在于含于未填充PVC缓冲管内的涂层光纤。表1示出了两个涂层光纤的剥离力的下降,光纤被置于由两种不同类型PVC缓冲材料,PVC#1和PVC#2制成的缓冲管内,硅氧烷基防水胶也与纤维的同时置于管内。
表1
由韧性缓冲管增塑剂的迁移造成的剥离力降低
材料类型 | 老化条件 | 剥离力下降 |
PVC#1 | 6个月@85℃ | 90% |
PVC#2 | 45天@110℃ | 35% |
聚烯烃 | 6个月@85℃ | -6% |
聚烯烃 | 45天@110℃ | -8% |
PVC#1含有苯二酸酯型增塑剂(苯二甲酸二异辛酯),PVC#2含有偏苯三酸酯型增塑剂(偏苯三酸三(2-乙基己基)酯)。由表1可看出,由PVC#1制成的缓冲管在85℃下老化6个月后,剥离力下降90%,90%的剥离力降低是由于苯二酸酯增塑剂容易迁移至光纤涂层而造成的;在第二个实验中,PVC#2制成的缓冲管在110℃老化45天,导致剥离力下降35%。与苯二酸酯型增塑剂相比,PVC#2中的偏苯三酸酯型增塑剂对剥离力的影响相对较小,但仍能观察到明显的剥离力降低。增塑剂由PVC韧性缓冲材料向光纤涂层的迁移由丙酮对光纤涂层上增塑剂的萃取及红外(FTIR)光谱的检测结果得到证实。萃取过程给出的结果说明,苯二酸酯型增塑剂的迁移量比偏苯三酸酯型增塑剂迁移量的4倍还多。这些有关两种级别PVC的试验结果是在使用对PVC影响最小的硅氧烷基防水胶的条件下获得的。使用聚烯烃或多元醇基胶体时,剥离力的降低更快、更剧烈。
作为比较,表1还示出了用根据本发明制造的热塑性聚烯烃高弹性体作为缓冲管的光纤,在与上述老化条件相似的条件下剥离力的降低。表1说明,当缓冲管是根据本发明由热塑性聚烯烃高弹性材料制成时,可观察到剥离力的增加。与增塑PVC样品相反,聚烯烃基材料没有可与光纤涂层相互作用的低分子量增塑剂。因此,由于老化试验中光纤涂层的进一步热塑化,剥离力实际上微量提高。本领域普通技术人员可明显看到,根据本发明由热塑性聚烯烃高弹性材料制成的缓冲管14明显消除与先有技术增塑PVC材料有关的剥离力问题。
本发明的热塑性聚烯烃高弹性体具有无增塑剂的优点,因而,使用任何类型防水胶都不发生增塑剂的析出,也不存在与有涂层的光纤相互作用的可能。因此,与多种胶体的兼容性赋予韧性热塑性聚烯烃高弹性缓冲管14以设计和成本上的优势。
本发明中用于形成缓冲管14的热塑性聚烯烃高弹性材料所体现的另一所希望的特点为高弹性材料高速应用于传输元12的能力。当以高速制造电信电缆元10时,缓冲材料常经受高剪切速率,如果挤出物的粘度太高(即熔体流动指数太低),可能导致挤出的缓冲管14表面不均匀或其它制造缺陷。对于缓冲管14以紧密构型置于光纤12周围的电信电缆元10来说,不均匀的表面可能通过引起光纤12的微量弯曲而导致信号衰减。微量弯曲引起的信号衰减也可能是由冷却及挤出成型的缓冲管14恢复弹性引起的挤出后收缩造成的。如果本发明中高弹性材料的熔体流动指数高于3,则上述提到的两个问题可降低至最小。现在,本领域普通技术人员将会认识到,本发明的缓冲管14可以任何众所周知的挤出成型工艺、以每分钟50米至每分钟几百米的线速度挤出。
除上述的检测外,还在85℃1小时后和100℃1小时后测定了各种增塑PVC材料和热塑性聚烯烃高弹性体的缓冲管的挤出后收缩率。对于增塑PVC材料的所有样品,85℃的挤出后收缩率约为5%,100℃的则在5.5%至7.5%之间,相反,在两个检测温度下,热塑性聚烯烃高弹性缓冲管的挤出后收缩率均在2%至3%之间。正如测试结果所显示的,PVC的挤出后收缩率高于热塑性聚烯烃高弹性体材料。挤出后收缩率必须降低至5%以下。光纤缓冲管通常设计成在给定的电缆长度内包含稍过量的光纤长度。因此,光纤承受应力前,整体模数低于玻璃的电缆结构可承受少量应变,由此,在安装和使用中,光纤可在无应变状态下操作。如果光纤经受拉伸应变,可能导致高衰减而致使电缆无用。光纤长度过量多少是一个电缆的关键设计特点,对于决定电缆的运行可靠性也是非常重要的。若过度的挤出后收缩导致光纤过量长度的增加,则在环境温度或低温使用时,光纤可能紧密接触(碰撞)缓冲管壁,缓冲管壁对光纤的约束是可引起衰减的另一原因,这样的约束对光纤施加横向张力,可将光纤的衰减程度提高到不能接受的水平。出于这些设计上的考虑,纤维光学产业对可容许的缓冲管收缩率提出了限制。美国农业部农村电力局公告1753F-601(PE-90)“填充纤维光缆的REA规格”的第10页中指出:“回缩应不超过5%”。符合这一指标及其它指标是纤维光缆设计的重要要求。
表2示出了本发明优选的一些缓冲材料组成的一些实例。表3给出了表2所列材料和上述的两类增塑PVC的一些测试结果。
表2
韧性缓冲材料的组成
材料 | 丙烯-乙烯共聚物 | 乙烯-辛烯共聚物- | 碳酸钙 | 二元乙丙(EPR)橡胶 | |
A | 丙烯-乙烯共聚物 | 100% | - | - | - |
B | 丙烯-乙烯共聚物 | 60% | - | 40% | - |
C | 韧性聚烯烃 | 40% | 35% | 25% | - |
D | 韧性聚烯烃 | 50% | 15% | 35% | - |
E | 韧性聚烯烃 | 55% | 5% | 40% | - |
F | 韧性聚烯烃 | 65% | 35% | - | - |
G | 韧性聚烯烃 | 50% | - | 35% | 15% |
表3
韧性缓冲材料的性质
材料 | 密度 | 模量(MPa)25℃ | 断裂伸长 | 可兼容的胶* | |
A | 丙烯-乙烯共聚物 | 0.88g/cc | 120 | 1100% | Si,OH,polyα-O(<60℃) |
B | 丙烯-乙烯共聚物 | 1.24g/cc | 220 | 400% | Si,OH,polyα-O(<60℃) |
C | 韧性聚烯烃 | 1.07g/cc | 120 | 285% | Si,OH |
D | 韧性聚烯烃 | 1.16g/cc | 140 | 270% | Si,OH |
E | 韧性聚烯烃 | 1.22g/cc | 160 | 270% | Si,OH |
F | 韧性聚烯烃 | 1.17g/cc | 188 | 300% | Si,OH,polyα-O(<60℃) |
G | 韧性聚烯烃 | 1.19g/cc | 120 | 250% | Si,OH,polyα-O(<60℃) |
H | PVC#1 | 1.44g/cc | 16 | 170% | Si |
I | PVC#2 | 1.32g/cc | 59 | 300% | Si |
*Si-硅氧烷基胶
OH-多元醇胶如Caschem 117-M2或Astor 600/1poly α-O-不含低分子量级分的聚α-烯烃胶,如Mastergel 1806或Henkel CF-363
由表3所示的结果可知,与增塑PVC相比,本发明的热塑性聚烯烃高弹性材料的密度较小,这也是本发明实现的优势之一。密度的降低是有利的,因为它允许电缆重量的降低。
由上述的讨论可以看出,本发明提供了一种具有置于缓冲管14内的光纤12的电信电缆元10,其中缓冲管14由在光纤电缆通常可能经历的温度下具有所希望弹性模量、具有改进了的与低成本触变性防水胶的兼容能力、能在高线速度下制造的热塑性聚烯烃高弹性材料制成。而且,本发明电信元10的缓冲材料不含卤素且阻燃。
虽然本发明已通过一个或几个具体实施方案进行了描述,应该清楚的是,本发明的其它实施方案不脱离本发明的宗旨和范围。因此,本发明仅由后附的权利要求书和其合理的解释限制。
Claims (17)
1.一种电信电缆元,它包含:
由热塑性聚烯烃高弹性材料制成的缓冲管,所用热塑性聚烯烃高弹性材料的室温弹性模量在500MPa以下,而-40℃下的弹性模量在1500MPa以下;和
置于缓冲管内的传输元。
2.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料的熔体流动指数高于3。
3.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料为丙烯与乙烯的共聚物。
4.权利要求3的电信电缆元,其中共聚物中乙烯的含量高于10%重量比。
5.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料为乙烯与辛烯的共聚物。
6.权利要求5的电信电缆元,其中共聚物中辛烯的含量高于10%重量比。
7.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料在室温下的断裂伸长率低于500%。
8.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料在室温下的断裂伸长率低于300%。
9.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料为含丙烯和乙烯的三元共聚物。
10.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料包括选自滑石、碳酸钙、碳黑、氢化铝和氢氧化镁的填充剂。
11.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料中含有阻燃材料。
12.权利要求1的电信电缆元,其中传输元为光纤。
13.权利要求12的电信电缆元,其中光纤以紧密构型置于缓冲管内。
14.权利要求12的电信电缆元,其中光纤以近于紧密构型置于缓冲管内。
15.权利要求1的电信电缆元,其中传输元为松散构型的多个光纤。
16.权利要求15的电信电缆元,其中光纤束以带状排列。
17.权利要求1的电信电缆元,其中热塑性聚烯烃高弹性材料在-40℃下的热膨胀系数为50×106/℃,85℃下的热膨胀系数为200×106/℃。
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- 1999-10-28 CN CN99123387.5A patent/CN1206662C/zh not_active Expired - Fee Related
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US9057857B2 (en) | 2013-06-28 | 2015-06-16 | Corning Optical Communications LLC | Fiber optic assembly for optical cable |
Also Published As
Publication number | Publication date |
---|---|
EP1024382A2 (en) | 2000-08-02 |
BR0000173A (pt) | 2000-09-12 |
JP3834168B2 (ja) | 2006-10-18 |
EP1024382A3 (en) | 2004-02-04 |
CN1262515A (zh) | 2000-08-09 |
JP2000221370A (ja) | 2000-08-11 |
US6215931B1 (en) | 2001-04-10 |
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