WO2022048019A1 - 全干式光缆及其制备方法 - Google Patents

全干式光缆及其制备方法 Download PDF

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Publication number
WO2022048019A1
WO2022048019A1 PCT/CN2020/128775 CN2020128775W WO2022048019A1 WO 2022048019 A1 WO2022048019 A1 WO 2022048019A1 CN 2020128775 W CN2020128775 W CN 2020128775W WO 2022048019 A1 WO2022048019 A1 WO 2022048019A1
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Prior art keywords
optical
layer
optical fiber
loose
dry
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PCT/CN2020/128775
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English (en)
French (fr)
Inventor
赵静
缪小明
乐梦龙
潘和平
缪斌
谭枫
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江苏中天科技股份有限公司
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Publication of WO2022048019A1 publication Critical patent/WO2022048019A1/zh

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    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4401Optical cables
    • G02B6/441Optical cables built up from sub-bundles
    • G02B6/4411Matrix structure
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4401Optical cables
    • G02B6/4429Means specially adapted for strengthening or protecting the cables
    • G02B6/44384Means specially adapted for strengthening or protecting the cables the means comprising water blocking or hydrophobic materials
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4479Manufacturing methods of optical cables

Definitions

  • the present application relates to the technical field of optical cables, and in particular, to a fully dry optical cable and a preparation method thereof.
  • the core of a conventional optical cable generally includes a loose tube, a plurality of optical fibers arranged in the loose tube, and a waterproof fiber paste filled between the optical fibers and the loose tube. Due to the existence of fiber paste, when the optical fiber network enters the access network and distribution network, it needs to spend a lot of cost and time to clean the paste, the fiber connection efficiency is low, and it is not clean and environmentally friendly. With the development of optical communication networks in the direction of large capacity and high speed, the number of optical cables deployed globally has surged, the workload of connection will gradually increase, and the corresponding maintenance difficulty and labor cost will also increase.
  • An all-dry optical cable including a cable core, an armor layer and an outer sheath
  • the cable core includes at least one loose tube, an optical unit placed in each of the loose tubes, and a water blocking layer.
  • the water layer is located on the inner wall of the loose tube and covers the periphery of the optical unit.
  • the optical unit includes a multi-layer optical fiber ribbon, each optical fiber ribbon includes a plurality of optical fibers, and the multiple optical fibers of each optical fiber ribbon are curable.
  • the resin coats and fixes the plurality of optical fibers.
  • the cable core includes a loose tube, an optical unit placed in the loose tube, and a water blocking layer.
  • the armoring layer is an armoring layer
  • the armoring layer is a unidirectional helically twisted armoring of a single fine round steel wire surrounding the loose tube.
  • the cable core includes a plurality of loose tubes, each loose tube has an optical unit and a water blocking layer, and the plurality of loose tubes take the center of the armor layer as the center of the circle and the outer edges are Circumferential distribution.
  • the cable core includes a first loose tube located in the center of the armor layer, a plurality of second loose tubes arranged around the first loose tube, and a plurality of second loose tubes arranged around the second loose tube of multiple third loose tubes.
  • the armoring layer is an armoring layer
  • the armoring layer is a steel-plastic composite tape longitudinally wrapped armor
  • the steel-plastic composite tape is longitudinally wrapped around the outer periphery of the cable core.
  • the fully dry optical cable further includes a water blocking yarn located between the plurality of loose tubes.
  • one of the optical units located at the center of the fully dry optical cable is formed by stacking 4 to 12 optical fiber ribbons, and each optical fiber ribbon includes 6 to 24 optical fibers.
  • the fully dry optical cable also includes a single-sided composite film water blocking tape located between the armoring layer and the outer sheath, and the single-sided composite film water blocking tape is wrapped on the armoring. Outside the layer, the polyester film of the single-sided laminated water blocking tape is inwardly covered with an armor layer.
  • a preparation method of an all-dry optical cable, for preparing the above-mentioned all-dry optical cable comprises the following steps:
  • optical fiber array placed in a curing mold, filling the curing mold with resin, and fixing the plurality of optical fibers together to form a flat optical fiber ribbon by ultraviolet light;
  • a loose tube wrapped around the periphery of the water blocking layer is formed by extrusion molding
  • One of the loose tubes or a plurality of loose tubes arranged around a center is used as a cable core, and the outer periphery of the cable core is covered with an armor layer; and the outer periphery of the armor layer is covered with an outer sheath.
  • the optical unit in the above all-dry optical cable adopts an optical fiber array, which is simple and convenient to operate and has high installation efficiency during the optical fiber splicing process; at the same time, the all-dry structure reduces the cleaning of filling grease, saves maintenance time and operation and maintenance costs, and is better realization of environmental friendliness.
  • FIG. 1 is a schematic structural diagram of a fully dry optical cable according to an embodiment of the present application.
  • FIG. 2 is a schematic structural diagram of a fully dry optical cable in another embodiment of the present application.
  • FIG. 3 is a flow chart of a method for manufacturing a fully dry optical cable according to an embodiment of the present application.
  • All dry fiber optic cable 100 cable core 10 loose tube 11 light unit 12 fiber optic ribbon 121 optical fiber 1211 water barrier 13 Armor 20 outer sheath 30 reinforcement 32 Water blocking tape 40 Water blocking yarn 50
  • FIG. 1 and FIG. 2 are schematic structural diagrams of an all-dry optical cable 100 in an embodiment provided by the present application.
  • the all-dry optical cable 100 includes a cable core 10 , an armor layer 20 and an outer sheath layer 30 .
  • the armor layer 20 is placed between the cable core 10 and the outer sheath 30 , and the armor layer 20 and the outer sheath 30 are used to protect the cable core 10 .
  • the cable core 10 includes at least one loose tube 11 , an optical unit 12 and a water blocking layer 13 disposed in each of the loose tubes 11 .
  • the water blocking layer 13 is located on the inner wall of the loose tube 11 and covers the periphery of the light unit 12 for preventing water or water vapor from entering the light unit 12 .
  • the optical unit 12 includes multiple layers of optical fiber ribbons 121 , each optical fiber ribbon 121 includes multiple optical fibers 1211 , and the multiple optical fibers 1211 of each optical fiber ribbon 121 are covered and fixed by using curable resin between the multiple optical fibers 1211 . .
  • the relative positions of all the optical fibers 1211 are fixed due to the resin curing of the optical fibers 1211 in the cable core 10.
  • the cable core 10 of the fully dry optical cable 100 as shown in FIG. 1 includes a loose tube 11 , an optical unit 12 and a water blocking layer 13 placed in the loose tube 11 .
  • the cable core 10 of the fully dry optical cable 100 as shown in FIG. 2 includes a plurality of loose tubes 11 , and each loose tube 11 has an optical unit 12 and a water blocking layer 13 therein.
  • the plurality of loose tubes 11 are distributed along the circumference with the center of the armor layer 20 as the center of the circle.
  • the cable core 10 includes 7 loose tubes 11, and adopts a "1+6" structure, with one loose tube 11 as the center, surrounded by 6 loose tubes 11 of the same size, Made of "SZ" twist.
  • the cable core 10 includes 9 loose tubes 11, and adopts a "1+8" structure, with one loose tube 11 as the center, surrounded by 8 loose tubes 11 of the same size and size , using "SZ" twisted.
  • the cable core 10 is a double-layer stranded cable core 10 structure, including a first loose tube 11 located in the center of the armor layer 20 , a first loose tube 11 disposed around the first loose tube 11 a plurality of second loose tubes 11 and a plurality of third loose tubes 11 arranged around the second loose tubes 11 .
  • the first is the "1+6+12" structure, with one loose tube 11 as the center, 6 loose tubes 11 in the inner layer, and 12 loose tubes 11 in the outer layer; or the “1+7+13" structure, With one loose tube 11 as the center, 7 loose tubes 11 in the inner layer and 13 loose tubes 11 in the outer layer; or “1+9+15" structure, with one loose tube 11 as the center, the inner layer 9 loose tubes 11 and 15 loose tubes 11 in the outer layer.
  • the cable core 10 is a double-layer stranded cable core 10 structure, it is not limited to the structure listed above, and a certain number of inner or outer loose tubes can be replaced by filling elements of the same size and specifications according to actual needs. 11.
  • the maximum number of cores of the optical cable can reach 2400 cores, which can be used for large-core, high-density optical cables for data center interconnection in the future to meet high communication capacity requirements.
  • a reinforcing element can be used to replace the central loose tube 11, wherein the reinforcing element may be a glass fiber reinforced plastic rod or a phosphating steel wire; or a reinforcing element covered with a plastic layer may be used, and the covered plastic layer may be Olefin material, low smoke halogen free material.
  • the material of the loose tube 11 can be polyolefin-modified polycarbonate (PC) or polycarbonate modified by other polymer materials, such as nylon (PA) modified PC, ABS modified PC; Material-modified polycarbonate, such as glass fiber, etc.; or other polymer materials, such as polybutylene terephthalate (PBT), high-density polyethylene (HDPE), modified polypropylene (PP); or
  • PC/PBT polyolefin-modified polycarbonate
  • PC/PP polypropylene
  • TPEE/PBT PE/PP
  • the optical unit 12 located at the center of the fully dry optical cable 100 is formed by stacking 4 to 12 optical fiber ribbons 121, each optical fiber ribbon 121 includes 6 to 24 optical fibers 1211, and the optical fibers 1211 are colored optical fibers 1211.
  • the optical fiber 1211 spectrum includes but is not limited to blue, orange, green, helium, gray, white, red, black, yellow, purple, pink, cyan, and the optical fiber 1211 beyond 12 cores can be identified and distinguished by a coloring ring.
  • the type of the optical fiber 1211 is G.657 optical fiber or G.652 optical fiber
  • the diameter of the coating layer is (240 ⁇ m ⁇ 250 ⁇ m) ⁇ 5 ⁇ m.
  • the diameter of the coating layer of the optical fiber 1211 is 180 ⁇ m ⁇ 200 ⁇ m.
  • the water blocking layer 13 can be a soft PET composite expansion water blocking tape with a thickness of 0.10mm to 0.15mm, a tensile strength of not less than 13N/cm, and a water expansion rate of not less than 4mm/min; short-term thermal stability The temperature is not lower than 250°C, the transverse shrinkage rate is not more than 25%, and the molding method is vertical wrapping.
  • the water-blocking layer 13 can also be a water-blocking powder coated on the surface of the light unit 12 , and can also be replaced by a water-blocking yarn with high water-swelling and high linear density.
  • the water blocking layer 13 is wrapped around the optical unit 12 to form a lap joint with a suitable width to avoid scratching the optical fiber 1211; the lap joint width is 0.5mm-1.5mm.
  • the armoring layer 20 may be a unidirectional helically twisted armoring of a single thin round steel wire, surrounding the loose tube 11 , and the number of twisted pieces is 16 to 24 pieces. A suitable twisting pitch is adopted to ensure that the steel wire is tightly covered and the entire cable core 10 is structurally rounded.
  • the armoring layer 20 can also be longitudinally wrapped with a steel-plastic composite tape with a thickness of 0.1 mm to 0.2 mm, and the steel-plastic composite tape is longitudinally wrapped around the outer periphery of the cable core 10 .
  • the armor layer 20 can also be made of non-metallic materials, such as glass fiber reinforced plastic rods, carbon fiber reinforced plastic rods; the shape can be round, flat, fan-shaped or other special-shaped structures.
  • the number of layers of the armoring layer 20 may be one layer, two layers or multiple layers.
  • the use of the armoring layer 20 can improve the tensile strength and lateral pressure resistance of the optical cable, and can meet the laying requirements of the all-dry optical cable in different application environments such as overhead, pipeline, and underwater.
  • the outer protective layer 30 can be made of high-density polyethylene with a thickness between 1.5 mm and 2.5 mm.
  • the outer sheath 30 can also be a nylon material, such as PA6, PA12, etc.; or a thermoplastic elastomer material, such as TPV, TPU, TPEE, etc.; or a low-smoke halogen-free flame retardant material.
  • the outer sheath 30 can also be symmetrically embedded with reinforcements 32 , and the reinforcements 32 are made of non-metallic materials, such as glass fiber reinforcement.
  • the fully dry optical cable 100 further includes a water blocking tape 40 .
  • the water blocking tape 40 is located between the armor layer 20 and the outer protective layer 30 , and the water blocking tape 40 is a single-sided laminated water blocking tape.
  • the single-sided composite film water blocking tape is wrapped outside the armoring layer 20 , and the ester film of the single-sided composite water blocking tape is covered with the armoring layer 20 inwardly, and is wrapped around the armoring layer 20 , the thickness of the composite film water blocking tape 40 is 0.2mm-0.3mm.
  • the water blocking tape 40 is located on the inner wall of the armoring layer 20 and is wrapped on the outside of the cable core 10 .
  • the yarn is made of aramid material with low linear density and low shrinkage to ensure the structural stability of the cable core 10 .
  • the fully dry optical cable 100 may further include a water blocking yarn 50 located between the plurality of loose tubes 11 .
  • 50 is a composite of polyester fiber and high water absorption material or water swellable material, the linear density is 3000m/kg ⁇ 10000m/kg, and the number can be designed according to needs, such as 4 to 8.
  • the present invention also provides a preparation method of the above-mentioned fully dry optical cable 100 , and the preparation method is as follows.
  • Step S310 Provide a plurality of optical fibers 1211 to form an optical fiber array by converging and combining with a paralleling die.
  • the optical fiber 1211 is actively paid off under constant tension control, and the pay-off tension is 0.6N-0.8N;
  • the optical fiber 1211 is a colored optical fiber 1211, and the optical fiber 1211 chromatogram includes but is not limited to blue, orange, green, heald, gray, White, red, black, yellow, purple, pink, cyan, and optical fibers 1211 with more than 12 cores are identified and distinguished by coloring rings.
  • Step S320 placing the optical fiber array in a curing mold, filling the curing mold with resin, and fixing the plurality of optical fibers 1211 together by ultraviolet light to form a flat optical fiber ribbon 121 .
  • the resin evenly coats all the optical fibers 1211, it also includes adjusting the resin coating pressure.
  • the optical fiber ribbon 121 has a smooth surface, no stickiness, no delamination, no loose fibers, and the overall flatness is not greater than 40 ⁇ m. In order to facilitate identification, the surface of the cured optical fiber ribbon can be printed and identified.
  • the resin adopts optical fiber 1211 with coating resin. It uses acrylic resin as the main raw material, adds suitable photoinitiators and auxiliary agents, and is a resin material that can be cured by ultraviolet light through polymerization reaction and compounding process. It comprises in parts by weight: polyacrylic resin: 85 to 95 parts; ultraviolet curing agent: 3 to 5 parts; ultraviolet light initiator: 5 to 8 parts; antioxidant: 1 to 2 parts; Dosage: 3 to 5 servings.
  • the optical fiber 1211 is combined with a coating resin, which can be cured by ultraviolet light. Before curing, the viscosity is 4500mPa ⁇ S ⁇ 5500mPa ⁇ S at 25°C.
  • the cured optical fiber ribbon 121 has good flexibility, excellent torsion resistance, and also has good separability and peelability. It is beneficial to the control of the attenuation stability of the optical fiber 1211 during the cabling process and the convenience of construction and connection, and it is more beneficial to continue the connection in a small space of the splice box.
  • Step S330 Laminate a predetermined number of optical fiber ribbons 121 through a doubling mold to form the optical unit 12 .
  • a cage stranding machine is used to spirally pay off the optical fiber ribbon 121 in one direction, the pay-off tension is 2N ⁇ 4N, and the predetermined twisting pitch is adjusted, such as 400mm ⁇ 800mm.
  • Step S340 longitudinally wrapping the water blocking layer 13 on the periphery of the light unit 12 .
  • the water blocking layer 13 adopts a constant tension to control the pay-off, and the pay-off tension is 0.8N to 1.2N.
  • the pay-off tension is 0.8N to 1.2N.
  • the longitudinal wrapping die and the extruder head die are separated from each other.
  • the center line is kept horizontal, and the front end of the longitudinal wrapping mold is a cylindrical hollow pipe, which can directly enter the position of the mold core.
  • the outer diameter of the pipe is the positive and negative deviation of the inner diameter of the mold core, which is 0.5mm; the inner diameter of the pipe is larger than the theoretical inner diameter of the forming sleeve, and the size is positive Deviation +0.5mm ⁇ +1.0mm; ensure that the water-blocking layer 13 has completed the vertical wrapping and lap joint when entering the extrusion mold, which can well avoid the water-blocking layer 13 being folded or incompletely covered when entering the mold , resulting in a bad edge overlap effect, which in turn affects the attenuation of the optical fiber ribbon 121, the water resistance of the casing and the roundness of the molding. It can be understood that the water-blocking layer 13 and the optical fiber ribbon 121 can be stacked by using a synchronous pay-off, and jointly enter the extrusion die through the vertical wrapping die.
  • Step S350 forming the loose tube 11 covering the periphery of the water blocking layer 13 by extrusion molding.
  • the water tank in the extrusion process is converted into a vacuum water tank, that is, the top of the water tank is pressed with a metal plate cover and a gasket is fastened, and the two ends are sealed with a copper plate, and the whole can form a sealed state.
  • the center of the copper plates at both ends is reserved for tube holes suitable for sleeve extrusion, and the center line is kept horizontal with the center line of the mold; the sizing copper sleeve with vacuum holes is flanged to the tube hole of the front copper plate, and the working state is
  • the vacuum is pumped by a water ring vacuum pump, so that the flow rate of the extracted water and air mixture is greater than the flow rate of the water tank, forming a vacuum pressure and promoting the cooling and shaping of the sleeve in the sizing copper sleeve.
  • the length of the sizing copper sleeve is 150 ⁇ 350mm, the inner diameter is the outer diameter of the theoretically formed loose tube 11, the positive deviation of the size is +0.5mm ⁇ +1.0mm; the diameter of the vacuum hole is 1.0mm ⁇ 1.5mm, and the adjacent interval is 2.0mm ⁇ 3.0mm , evenly distributed on the surface of the sizing copper sleeve, and the vacuum pressure is 0.5Bar ⁇ 10Bar.
  • the excess length of the optical fiber ribbon 121 can be controlled at 0-3 ⁇ , and the transmission performance of the optical fiber 1211 is stable. In this way, by selecting sizing copper sleeves with different inner diameters and controlling the vacuum pressure, dry-type strip-shaped loose tubes 11 with different diameters can be obtained. Stable, smooth surface, uniform and rounded outer diameter, and out-of-roundness not more than 3%.
  • Step S360 use one of the loose tubes 11 or a plurality of loose tubes 11 arranged around a center as the cable core 10 , and coat the outer periphery of the cable core 10 with an armor layer 20 .
  • the armoring method of the armoring layer 20 can be unidirectional helical stranded armoring, longitudinal wrapping armoring, gap armoring or sparse armoring, and the specific armoring method is determined according to the material and requirements of the armoring layer 20 .
  • the number of layers of the armoring layer 20 may be one layer, two layers or multiple layers.
  • the armoring layer 20 before wrapping the armoring layer 20 on the periphery of the cable core, it also includes wrapping the water blocking tape 40 on the periphery of the cable core 10, and the armoring layer 20 wraps the outer periphery of the cable core 10.
  • the outer periphery of the water blocking strip 40 is described. Outside the water blocking tape 40, a tying yarn can also be wound, and the tying yarn is made of aramid material with low linear density and low shrinkage.
  • Step S370 Coating the outer sheath 30 on the periphery of the armor layer 20 .
  • the outer protective layer 30 is made of high-density polyethylene with a thickness of 1.5mm ⁇ 2.5mm.
  • a single-sided composite water-blocking tape is also coated on the outer periphery of the armor layer 20, and the ester film of the single-sided composite water-blocking tape faces the inner surface of the armor layer. 20.
  • the wrapping method is wrapping, and the thickness of the laminated water-blocking tape 40 is determined according to needs, such as 0.2 mm to 0.3 mm.
  • the outer protective layer 30 is wrapped around the periphery of the single-sided composite film water blocking tape.
  • the optical unit 12 in the above-mentioned all-dry optical cable 100 adopts an optical fiber array, which is simple and convenient to operate and has high installation efficiency during the connection process of the optical fiber 1211; at the same time, the all-dry structure reduces the cleaning of filling grease and saves maintenance time and operation and maintenance costs. , to better achieve environmental friendliness.

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Abstract

一种全干式光缆(100),包括缆芯(10)、铠装层(20)及外护层(30),缆芯(10)包括至少一松套管(11)、置于每一松套管(11)内的光单元(12)及阻水层(13),阻水层(13)位于松套管(11)内且包覆于光单元(12)外围,光单元(12)包括多层光纤带(121),每一光纤带(121)包括多根光纤(1211),每一光纤带(121)的多根光纤(1211)采用可固化的树脂将多根光纤(1211)包覆固定。还提供了全干式光缆(100)的制备方法。全干式光缆(100)中的光单元(12)采用光纤带(121)结构,接续简单方便、效率高;同时,全干式结构减少填充油膏的清理,节约维护时间与运维成本,更好的实现环境友好。

Description

全干式光缆及其制备方法 技术领域
本申请涉及光缆技术领域,尤其涉及一种全干式光缆及其制备方法。
背景技术
由于光缆通信具有速度快、传输质量好等优点,光缆通信的应用越来越广泛,人类信息传递也越来越离不开光缆。常规光缆的缆芯一般包括由松套管、设置于松套管内的多根光纤及填充于光纤与松套管之间的防水纤膏。由于纤膏的存在,当光纤网络进入接入网和配线网时,需要花费大量的成本和时间去清理油膏,光纤接续效率低,也不清洁环保。随着光通信网络向着大容量、高速率的方向推进,全球部署的光缆数量激增,接续工作量会逐渐增大,相应的维护难度和人工成本也增加。
发明内容
有鉴于此,有必要提供可提高安装效率的一种全干式光缆及其制备方法。
一种全干式光缆,包括缆芯、铠装层及外护层,所述缆芯包括至少一松套管、置于每一所述松套管内的光单元及阻水层,所述阻水层位于所述松套管内壁且包覆于所述光单元外围,所述光单元包括多层光纤带,每一光纤带包括多根光纤,每一光纤带的多根光纤采用可固化的树脂将所述多根光纤包覆固定。
进一步地,所述缆芯包括一松套管、置于所述一松套管内的一光单元及一阻水层。
进一步地,所述铠装层为铠装层,所述铠装层为单细圆钢丝单向螺旋绞合铠装,围绕在所述松套管的四周。
进一步地,所述缆芯包括多个松套管、每一松套管内均具有一光单元及一阻水层,所述多个松套管以所述铠装层的中心为圆心向外沿圆周分布。
进一步地,所述缆芯包括位于所述铠装层的中心的第一松套管、绕所述第一松 套管设置的多个第二松套管及绕所述第二松套管设置的多个第三松套管。
进一步地,所述铠装层为铠装层,所述铠装层为钢塑复合带纵包铠装,所述钢塑复合带纵包于所述缆芯的外围。
进一步地,所述全干式光缆还包括位于多个松套管之间的阻水纱。
进一步地,位于所述全干式光缆中心处的一所述光单元采用4根~12根光纤带叠加而成,每根光纤带包括6~24根光纤。
进一步地,所述全干式光缆还包括位于所述铠装层与所述外护层之间的单面复膜阻水带,所述单面复膜阻水带包覆于所述铠装层外,所述单面复膜阻水带的聚酯膜面向内包覆铠装层。
一种全干式光缆的制备方法,用于制备上述的全干式光缆,包含以下步骤:
提供多根光纤经并线模具汇聚组合形成一光纤阵列;
将所述光纤阵列放置于固化模具中,并在固化模具中填充树脂,经紫外光固定使所述多根光纤固定在一起形成扁平的光纤带;
将预定数量的光纤带经并线模具层叠形成光单元;
纵包阻水层于所述光单元的外围;
通过挤塑加工成型包覆于所述阻水层外围的松套管;
将一所述松套管或绕一中心排布的多个松套管作为缆芯,并在缆芯的外围包覆铠装层;及在所述铠装层的外围包覆外护层。
上述全干式光缆中的光单元采用光纤阵列,在光纤接续过程中操作简单方便、安装效率高;同时,全干式结构减少了填充油膏的清理,节约维护时间与运维成本,更好的实现环境友好。
附图说明
图1为本申请一实施方式中的一种全干式光缆的结构示意图。
图2为本申请另一实施方式中的一种全干式光缆的结构示意图。
图3为本申请一实施方式中的一种全干式光缆的制备方法的流程图。
主要元件符号说明
全干式光缆 100
缆芯 10
松套管 11
光单元 12
光纤带 121
光纤 1211
阻水层 13
铠装层 20
外护层 30
加强件 32
阻水带 40
阻水纱 50
如下具体实施方式将结合上述附图进一步说明本申请。
具体实施方式
为了能够更清楚地理解本发明实施例的上述目的、特征和优点,下面结合附图和具体实施方式对本发明进行详细描述。需要说明的是,在不冲突的情况下,本申请的实施方式中的特征可以相互组合。
在下面的描述中阐述了很多具体细节以便于充分理解本发明实施例,所描述的实施方式仅是本发明一部分实施方式,而不是全部的实施方式。基于本发明中的实施方式,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施方式,都属于本发明实施例保护的范围。
除非另有定义,本文所使用的所有的技术和科学术语与属于本发明实施例的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施方式的目的,不是旨在于限制本发明实施例。
请参阅图1及图2,为本申请提供的一实施方式中的一种全干式光缆100的结 构示意图。所述全干式光缆100包括缆芯10、铠装层20及外护层30。所述铠装层20置于所述缆芯10与所述外护层30之间,所述铠装层20与所述外护层30用于保护缆芯10。所述缆芯10包括至少一松套管11、置于每一所述松套管11内的光单元12及阻水层13。所述阻水层13位于所述松套管11内壁且包覆于所述光单元12外围,用于防止水或水汽进入到光单元12。所述光单元12包括多层光纤带121,每一光纤带121包括多根光纤1211,每一光纤带121的多根光纤1211之间采用可固化的树脂将所述多根光纤1211包覆固定。所述缆芯10中的光纤1211由于树脂固化使得所有光纤1211的相对位置固定,在与其他对应的元件连接时,将一根光纤1211对准元件上对应的位置,其他光纤1211也将对应连接到元件上,安装简单方便,提高了安装效率。
具体地,如图1所示的全干式光缆100的缆芯10包括一松套管11、置于所述一松套管11内的一光单元12及一阻水层13。如图2所述的全干式光缆100的缆芯10包括多个松套管11、每一松套管11内均具有一光单元12及一阻水层13。所述多个松套管11以所述铠装层20的中心为圆心向外沿圆周分布。在一实施方式中,所述缆芯10包括7根松套管11,采用“1+6”结构,以1根松套管11为中心,四周环绕6根相同规格尺寸的松套管11,采用“SZ”绞合而成。在另一实施方式中,所述缆芯10包括9根松套管11,采用“1+8”结构,以1根松套管11为中心,四周环绕8根相同规格尺寸的松套管11,采用“SZ”绞合而成。在另一实施方式中,所述缆芯10为双层绞合缆芯10结构,包括位于所述铠装层20的中心的第一松套管11、绕所述第一松套管11设置的多个第二松套管11及绕所述第二松套管11设置的多个第三松套管11。第一如“1+6+12”结构,以1根松套管11为中心,内层6根松套管11,外层12根松套管11;或“1+7+13”结构,以1根松套管11为中心,内层7根松套管11,外层13根松套管11;或“1+9+15”结构,以1根松套管11为中心,内层9根松套管11,外层15根松套管11。可以理解,所述缆芯10为双层绞合缆芯10结构时,不限于上述列举的结构,可根据实际需要,采用相同尺寸规格的填充元件替代一定数量的内层或者外层松套管11。可以理解,采用上述的全干式光缆100的缆芯结构,光缆最大芯数可达到2400芯,可用于未来数据中心互联的大芯数、 高密度光缆,满足高通信容量需求。进一步地,可根据实际应用需求,采用加强元件替代中心的松套管11,其中加强元件可为玻璃纤维增强塑料杆、磷化钢丝;或者采用被覆塑料层的加强元件,被覆塑料层可为聚烯烃材料、低烟无卤材料。
所述松套管11的材料可为聚烯烃改性的聚碳酸酯(PC)或其他高分子材料改性的聚碳酸酯,如尼龙(PA)改性PC,ABS改性PC;或采用无机材料改性的聚碳酸酯,如玻璃纤维等;或其他高分子材料,如聚对苯二甲酸丁二醇酯(PBT)、高密度聚乙烯(HDPE)、改性聚丙烯(PP);或采用两种高分子材料进行双层共挤形成的复合松套管11替代,如PC/PBT、PC/PP、TPEE/PBT、PE/PP等。
位于所述全干式光缆100中心处的一所述光单元12采用4根~12根光纤带121叠加而成,每根光纤带121包括6~24根光纤1211,所述光纤1211为着色光纤1211,光纤1211色谱包括但不局限于蓝、橙、绿、综、灰、白、红、黑、黄、紫、粉红、青绿,超出12芯的光纤1211可着色环进行辨识区分。在一实施方式中,所述光纤1211的类型为G.657光纤、G.652光纤,涂覆层直径为(240μm~250μm)±5μm。在另一实施方式中,所述光纤1211的涂覆层直径为180μm~200μm。
所述阻水层13可为一种质地柔软的PET复合膨胀阻水带,厚度在0.10mm~0.15mm,抗张强度不小于13N/cm,吸水膨胀速率不小于4mm/min;短期热稳定性温度不低于250℃,横向收缩率不超过25%,成型方式为纵包。所述阻水层13也可为涂敷于所述光单元12表面的阻水粉,还可用高吸水膨胀、高线密度的阻水纱替代。阻水层13包覆在所述光单元12的周围,形成适宜宽度的搭接,避免剐蹭光纤1211;搭接宽度为0.5mm~1.5mm。
所述铠装层20可如图1所示,为单细圆钢丝单向螺旋绞合铠装,围绕在松套管11的四周,绞合根数为16根~24根。采用合适的绞合节距,保证钢丝紧密包覆、整个缆芯10结构圆整。所述铠装层20也可如图2所示,为钢塑复合带纵包铠装,厚度为0.1mm~0.2mm,所述钢塑复合带纵包于所述缆芯10的外围。所述铠装层20也可采用非金属材料,如玻璃纤维增强塑料杆,碳纤维增强塑料杆;形状可为圆形、扁平、扇形或其他异形结构。所述铠装层20的层数可为一层、双层或多层。采用所述铠装层20,可提高光缆的抗拉强度和抗侧压性能,能满足全干式光缆在架空、 管道、水下等不同应用环境的敷设需求。
所述外护层30可为高密度聚乙烯材质,厚度在1.5mm~2.5mm之间。所述外护层30也可为尼龙材料,如PA6、PA12等;或热塑性弹性体材料,如TPV、TPU、TPEE等;或低烟无卤阻燃材料。在一实施方式中,所述外护层30还可如图2所示,在所述外护层30中对称地嵌入有加强件32,所述加强件32采用非金属材料,如玻璃纤维增强塑料杆、芳纶纤维增强塑料杆、碳纤维增强塑料杆。
所述全干式光缆100还包括阻水带40。在如图1所示的实施方式中,所述阻水带40位于所述铠装层20与所述外护层30之间,所述阻水带40为单面复膜阻水带。所述单面复膜阻水带包覆于所述铠装层20外,所述单面复膜阻水带的酯膜面向内包覆铠装层20,绕包于所述铠装层20,所述复膜阻水带40厚度为0.2mm~0.3mm。如图2所示的实施方式中,所述阻水带40位于所述铠装层20的内壁,包覆于所述缆芯10外,所述阻水带40外还可缠绕扎纱,扎纱采用低线密度、低收缩的芳纶材料,保证所述缆芯10的结构稳定。
所述全干式光缆100包括多个松套管11时,如图2所示,所述全干式光缆100还可包括位于多个松套管11之间的阻水纱50,阻水纱50为聚酯纤维与高吸水性材料或吸水膨胀性材料复合而成,线密度为3000m/kg~10000m/kg,根数可根据需要设计,如为4根~8根。
请参阅图3,本发明还提供了上述全干式光缆100的制备方法,制备方法如下。
步骤S310:提供多根光纤1211经并线模具汇聚组合形成一光纤阵列。所述光纤1211在恒定张力控制下主动放线,放线张力为0.6N~0.8N;所述光纤1211为着色光纤1211,光纤1211色谱包括但不局限于蓝、橙、绿、综、灰、白、红、黑、黄、紫、粉红、青绿,超出12芯的光纤1211通过着色环进行辨识区分。
步骤S320:将所述光纤阵列放置于固化模具中,并在固化模具中填充树脂,经紫外光固定使所述多根光纤1211固定在一起形成扁平的光纤带121。具体地,为了保证树脂均匀的包覆所有光纤1211,还包括调节树脂涂敷压力。所述光纤带121表面光滑,不粘黏,无分层、无散纤,整体平整度不大于40μm。为了便于识别,可在固化后的光纤带表面进行印字标识。
所述树脂采用光纤1211并带用涂敷树脂,是以丙烯酸树脂为主要原料,添加合适的光引发剂和助剂,经聚合反应、复配工艺制得的可通过紫外光固化的树脂材料,其按重量份数包含:聚丙烯酸树脂:85份~95份;紫外光固化剂:3份~5份;紫外光引发剂5份~8份;抗氧化剂:1份~2份;高分子助剂:3份~5份。所述光纤1211并带用涂敷树脂,可通过紫外光固化,固化前25℃下粘度为4500mPa·S~5500mPa·S,固化后在特定(2.5%弹变,23℃下)弹性模量在600MPa~800MPa,断裂伸长率不小于25%,断裂强度不小于20MPa;固化后的光纤带121具有较好的柔韧性,抗扭转性能优异,同时具有很好的可分离性和剥离性,有利于光纤1211在成缆过程中衰减稳定性的控制及施工接续的便利,更有利于在较小接头盒空间内续接盘留。
步骤S330:将预定数量的光纤带121经并线模具层叠形成光单元12。其中,在放线时,采用笼绞机对光纤带121单向螺旋放线,放线张力为2N~4N,调节预定的绞合节距如400mm~800mm。
步骤S340:纵包阻水层13于所述光单元12的外围。具体地,阻水层13采用恒定张力控制放线,放线张力为0.8N~1.2N,在进入挤塑机头前,通过特定的纵包模具,其中纵包模具与挤塑机头模具的中心线保持水平,且纵包模具前端部分为圆柱形空心导管,可直接进入模芯位置,导管外径为模芯内径尺寸的正负偏差0.5mm;导管内径大于理论成型套管内径,尺寸正偏差+0.5mm~+1.0mm;保证阻水层13在进入挤塑模具时已完成纵包搭接,可以很好的避免阻水层13在进入模具时出现翻折或是包覆不全的情况,造成不良的搭边效果,进而影响光纤带121衰减、套管阻水和成型圆整度。可以理解,阻水层13和光纤带121层叠可采用同步放线,共同通过纵包模具进入挤塑模具。
步骤S350:通过挤塑加工成型包覆于所述阻水层13外围的松套管11。其中,在挤塑成型松套管11时,将挤塑过程中的水槽改装为真空水槽,即在水槽上方用金属板盖压及垫圈紧固,两端用铜板密封,整体可形成密封状态。其中两端铜板中心预留适合套管挤出成型的管孔,其中心线与模具中心线保持水平;将带有真空孔的定径铜套用法兰固定在前端铜板的管孔上,工作状态时,定径铜套充分浸没在水 槽中,由水环式真空泵抽真空,使抽出的水、空气混合物流量大于水槽流量,形成真空压力,促进套管在定径铜套内冷却定型。定径铜套长度为150~350mm,内径为理论成型松套管11外径,尺寸正偏差+0.5mm~+1.0mm;真空孔直径为1.0mm~1.5mm,相邻间隔2.0mm~3.0mm,均匀分布在定径铜套表面,真空压力为0.5Bar~10Bar。松套管11成型后,光纤带121余长可控制在0~3‰,光纤1211传输性能稳定。如此,可通过选择不同内径的定径铜套及控制真空压力,获得不同直径的干式带状松套管11,松套管11规格尺寸可分布在4.5mm~20.0mm;松套管11成型稳定,表面光滑,外径均匀圆整,尺寸不圆度不大于3%。
步骤S360:将一所述松套管11或绕一中心排布的多个松套管11作为缆芯10,并在缆芯10的外围包覆铠装层20。铠装层20的铠装方式可以采用单向螺旋绞合铠装、纵包铠装、间隙铠装或稀疏铠装,具体的铠装方式根据铠装层20的材料及需求确定。所述铠装层20的层数可为一层、双层或多层。在一实施方式中,在包覆铠装层20于所述缆芯的外围前,还包括将阻水带40包覆于所述缆芯10的外围,所述铠装层20包覆于所述阻水带40的外围。所述阻水带40外还可缠绕扎纱,扎纱采用低线密度、低收缩的芳纶材料。
步骤S370:在所述铠装层20的外围包覆外护层30。在一实施方式中,所述外护层30采用高密度聚乙烯,厚度在1.5mm~2.5mm。在一实施方式中,在步骤S370前,还包覆单面复膜阻水带于所述铠装层20的外围,所述单面复膜阻水带的酯膜面向内包覆铠装层20,包覆方式为绕包,所述复膜阻水带40的厚度根据需要确定,如为0.2mm~0.3mm。所述外护层30包覆于所述单面复膜阻水带的外围。
上述全干式光缆100中的光单元12采用光纤阵列,在光纤1211接续过程中操作简单方便、安装效率高;同时,全干式结构减少了填充油膏的清理,节约维护时间与运维成本,更好的实现环境友好。
本技术领域的普通技术人员应当认识到,以上的实施方式仅是用来说明本申请,而并非用作为对本申请的限定,只要在本申请的实质精神范围内,对以上实施方式所作的适当改变和变化都落在本申请要求公开的范围内。

Claims (10)

  1. 一种全干式光缆,包括缆芯、铠装层及外护层,其特征在于,所述缆芯包括至少一松套管、置于每一所述松套管内的光单元及阻水层,所述阻水层位于所述松套管内壁且包覆于所述光单元外围,所述光单元包括多层光纤带,每一光纤带包括多根光纤,每一光纤带的多根光纤之间采用可固化的树脂将所述多根光纤包覆固定。
  2. 如权利要求1所述的全干式光缆,其特征在于:所述缆芯包括一松套管、置于所述一松套管内的一光单元及一阻水层。
  3. 如权利要求1所述的全干式光缆,其特征在于:所述铠装层为铠装层,所述铠装层为单细圆钢丝单向螺旋绞合铠装,围绕在所述松套管的四周。
  4. 如权利要求1所述的全干式光缆,其特征在于:所述缆芯包括多个松套管、每一松套管内均具有一光单元及一阻水层,所述多个松套管以所述铠装层的中心为圆心向外沿圆周分布。
  5. 如权利要求4所述的全干式光缆,其特征在于:所述缆芯包括位于所述铠装层的中心的第一松套管、绕所述第一松套管设置的多个第二松套管及绕所述第二松套管设置的多个第三松套管。
  6. 如权利要求4所述的全干式光缆,其特征在于:所述铠装层为铠装层,所述铠装层为钢塑复合带纵包铠装,所述钢塑复合带纵包于所述缆芯的外围。
  7. 如权利要求4所述的全干式光缆,其特征在于:所述全干式光缆还包括位于多个松套管之间的阻水纱。
  8. 如权利要求1所述的全干式光缆,其特征在于:位于所述全干式光缆中心处的一所述光单元采用4根~12根光纤带叠加而成,每根光纤带包括6~24根光纤。
  9. 如权利要求1所述的全干式光缆,其特征在于:所述全干式光 缆还包括位于所述铠装层与所述外护层之间的单面复膜阻水带,所述单面复膜阻水带包覆于所述铠装层外,所述单面复膜阻水带的聚酯膜面向内包覆铠装层。
  10. 一种全干式光缆的制备方法,用于制备权利要求1~9任一所述的全干式光缆,其特征在于,包含以下步骤:
    提供多根光纤经并线模具汇聚组合形成一光纤阵列;
    将所述光纤阵列放置于固化模具中,并在固化模具中填充树脂,经紫外光固定使所述多根光纤固定在一起形成扁平的光纤带;
    将预定数量的光纤带经并线模具层叠形成光单元;
    纵包阻水层于所述光单元的外围;
    通过挤塑加工成型包覆于所述阻水层外围的松套管;
    将一所述松套管或绕一中心排布的多个松套管作为缆芯,并在缆芯的外围包覆铠装层;及在所述铠装层的外围包覆外护层。
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