WO2022262124A1 - 微缆及其制造方法、填充装置 - Google Patents

微缆及其制造方法、填充装置 Download PDF

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Publication number
WO2022262124A1
WO2022262124A1 PCT/CN2021/116614 CN2021116614W WO2022262124A1 WO 2022262124 A1 WO2022262124 A1 WO 2022262124A1 CN 2021116614 W CN2021116614 W CN 2021116614W WO 2022262124 A1 WO2022262124 A1 WO 2022262124A1
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WIPO (PCT)
Prior art keywords
optical fiber
optical
sealant
fiber bundle
microcable
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PCT/CN2021/116614
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English (en)
French (fr)
Inventor
赵静
缪小明
钱慧慧
缪斌
谭枫
李新建
Original Assignee
江苏中天科技股份有限公司
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Priority to CA3223526A priority Critical patent/CA3223526A1/en
Publication of WO2022262124A1 publication Critical patent/WO2022262124A1/zh

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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
    • G02B6/4479—Manufacturing methods of optical cables

Definitions

  • the present application relates to the technical field of microcables, in particular to a microcable, a manufacturing method thereof, and a filling device.
  • Micro-cables are also called micro-optical cables. Generally, under the same optical performance, micro-cables have smaller outer diameter and lighter weight than traditional optical cables with the same number of cores. Therefore, micro-cables are more and more widely used.
  • Microcables can be laid by air blowing.
  • compressed air is used to blow the sub-pipes into the laid main pipes, and then according to the development needs, compressed air is used to blow the microcables in batches. Blow into the sub tube.
  • the mother pipe is usually a silicon core pipe
  • the daughter pipe is usually a high-density polyethylene pipe.
  • the mother pipe and the daughter pipe can be used to protect the microcable.
  • the air-blow laying method can simplify the construction process and save construction costs.
  • the purpose of this application is to provide a microcable, its manufacturing method, and filling device, which are used to reduce the damage to the performance of the microcable during the process of blowing the microcable into the sub-duct.
  • the present application discloses a microcable, the microcable includes a cable core and an outer sheath covering the outer peripheral surface of the cable core, and the cable core includes a central strength member, a plurality of optical units and a sealant A plurality of optical units are twisted around the central reinforcement, and the sealant is filled in the twisted gaps of the plurality of optical units.
  • the microcable disclosed in the present application includes a cable core and an outer sheath, the outer sheath covers the outer peripheral surface of the cable core, the cable core includes a central strengthening member and a plurality of optical units twisted around the central strengthening member, The twisted gaps of multiple optical units are filled with sealant.
  • the sealant can fill the stranding gap of the optical unit, and the sealant can bond with the optical unit, the outer sheath and other parts, without leaving a gap in the area surrounded by the outer sheath.
  • the material of the sealant includes an active resin, a thickener and a tackifier, wherein the thickener and the tackifier are uniformly mixed in the active resin.
  • the hardness of the sealant after curing is 35HA-45HA, and the density of the sealant after curing is 1.2g/cm 3 -1.4g/cm 3 .
  • the optical unit includes an optical fiber bundle
  • the optical fiber bundle includes a plurality of optical fibers and a cured resin
  • the plurality of optical fibers are distributed in the cured resin at intervals in a bundle.
  • the cured resin is a thermosetting resin
  • the optical unit also includes a secondary coating layer covering the outer peripheral surface of the optical fiber bundle, and the material of the secondary coating layer includes polybutylene terephthalate ester, and the thickness of the secondary coating layer is 0.1 mm to 0.3 mm.
  • the number of optical fibers in each optical fiber bundle is 12 or 24;
  • the diameter of the optical fiber bundle is 0.9 mm to 1.2 mm, and the diameter of the optical unit is 1.3 mm to 1.7 mm;
  • the diameter of the optical fiber bundle is 1.4mm ⁇ 1.7mm, and the diameter of the optical unit is 1.6mm ⁇ 2.3mm.
  • the cured resin is a photocurable resin
  • the photocurable resin includes a base resin, a photosensitizer and an active agent, wherein the photosensitizer and the active agent are uniformly mixed in the base resin.
  • the number of optical fibers in each optical fiber bundle is 12 or 24;
  • the diameter of the optical fiber bundle is 1.0 mm to 1.5 mm;
  • the diameter of the optical fiber bundle is 1.5mm ⁇ 2.0mm.
  • the material of the outer sheath is at least one of polyurethane elastomer, polyvinyl chloride, thermoplastic elastomer, and thermoplastic polyester elastomer; the thickness of the outer sheath is 0.4 mm to 0.8 mm.
  • the present application discloses a filling device.
  • the filling device includes a glue injection and line mold, a glue injection valve, a sealant pump and an air source.
  • a filling channel and a glue injection mold are arranged in the glue injection and line mold. aisle,
  • the filling channel includes a filling inlet and a filling outlet, the central reinforcement and a plurality of light units penetrate the filling channel from the filling inlet, and pass out of the filling channel from the filling outlet; one end of the glue injection channel It communicates with the injection valve, and the other end communicates with the filling channel; both the sealant pump and the air source communicate with the injection valve;
  • the sealant pump is used to pump sealant into the glue injection valve;
  • the air source is used to adjust the air pressure in the glue injection valve to control the glue output speed of the glue injection valve;
  • the filling channel is used for filling the sealant into the twisted gaps of the plurality of optical units.
  • the filling device disclosed in this application pumps the sealant into the glue injection valve through the sealant pump, controls the glue discharge speed of the glue injection valve through the air source, and the glue injection valve injects the sealant into the sealing channel, and the sealant The sealed channel and the filled channel are finally filled in the twisted gaps of the optical unit in the filled channel.
  • the glue discharge speed of the glue injection valve can be adjusted, it can ensure that the sealant is fully filled in the twisted gaps of multiple optical units, improving the airtightness of the cable core.
  • the present application discloses a method for manufacturing a microcable, the method for manufacturing a microcable includes:
  • An outer sheath is extruded on the outer peripheral surface of the cable core, and the outer sheath and the cable core jointly form a microcable.
  • the manufacturing method of the microcable disclosed in the present application includes providing a central strength member and a plurality of optical fibers; laying out the plurality of optical fibers evenly, making the plurality of optical fibers pass through a paralleling mold, so that the plurality of optical fibers are spaced apart in a bundle Arrangement: draw multiple optical fibers arranged in bundles at intervals into the coating mold, so that multiple optical fibers are distributed in bundles at intervals inside the cured resin to form uncured optical fiber bundles; uncured optical fiber bundles are cured device to form a cured optical fiber bundle; pull the cured optical fiber bundle into the first extrusion mold, and extrude a secondary coating layer on the outer peripheral surface of the cured optical fiber bundle; the cured optical fiber bundle and the secondary coating layer Form an optical unit; twist multiple optical units around the central strength member, and fill the sealant in the stranding gap of the multiple optical units; the central strength member, multiple optical units and sealant together form a cable core; in the cable core The outer
  • the sealant in the microcable formed through the above steps can fill the stranding gaps of multiple optical units, and the sealant can be bonded to the optical unit, the outer sheath, etc., without leaving gaps in the area surrounded by the outer sheath .
  • There is no gap in the area surrounded by the outer sheath so there will be no pressure difference between the inside and outside of the sheath, and the sealant can withstand greater pressure after curing, and the force balance inside and outside the outer sheath can be maintained when the microcable is laid by air blowing , the microcable will not be deformed or has a small amount of deformation, so that the microcable is less damaged during the process of blowing the microcable manufactured in the above steps into the sub-pipe.
  • drawing the cured optical fiber bundle into an extrusion mold, and forming a secondary coating layer on the outer peripheral surface of the cured optical fiber bundle includes:
  • the above-mentioned filling device is used.
  • FIG. 1 is a schematic structural diagram of a microcable provided in an embodiment of the present application.
  • Fig. 2 is the structural representation of the cable core that the embodiment of the present application provides;
  • Fig. 3 is a schematic structural diagram of a filling device provided in an embodiment of the present application.
  • sealant 20: outer sheath
  • the microcable includes a cable core and an outer sheath covering the cable core.
  • the cable core includes a plurality of twisted optical units, and the twisted gaps of the plurality of optical units are filled with multiple water-blocking yarns. , There are gaps between multiple water-blocking yarns, and there are also gaps between the water-blocking yarns, the optical unit and the outer sheath, resulting in gaps in the area surrounded by the outer sheath.
  • the outside of the outer sheath of the microcable When laying the microcable by air blowing, the outside of the outer sheath of the microcable receives a large gas pressure, while the gas pressure in the gap in the area surrounded by the outer sheath is small, and the gas inside and outside the outer sheath produces a pressure difference, resulting in Deformation of the microcable.
  • there may be micropores on the surface of the outer sheath so that the gas outside the outer sheath enters the area surrounded by the outer sheath along the micropores, and surrounds the area along the outer sheath. The movement of the gap in the area will eventually cause the outer sheath to bulge or even burst, which will damage the performance of the microcable.
  • the microcable provided by the embodiment of the present application fills the twisted gaps of multiple optical units with sealant, the sealant can fill the twisted gaps of the optical units, and the sealant can be connected with the optical units, the outer sheath and other parts Bonded so as not to leave gaps in the area enclosed by the outer sheath.
  • the sealant can withstand a large pressure after curing, even if there are structures such as air bubbles in the sealant, The force balance inside and outside the outer sheath can still be maintained, and the micro-cable will not be deformed or deformed slightly.
  • the embodiment of the present application provides a microcable, including a cable core 10 and an outer sheath 20 covering the outer peripheral surface of the cable core 10, the cable core 10 includes a central strength member 12, a plurality of optical fibers The unit 11 and the sealant 13 , the plurality of optical units 11 are twisted around the central reinforcement 12 , and the sealant 13 is filled in the twisted gaps of the plurality of optical units 11 .
  • the sealant 13 can fill the twisted gaps of multiple optical units 11, and the sealant 13 can be bonded to the optical units 11, the outer sheath 20, etc., so as not to leave any gaps in the area surrounded by the outer sheath 20. Gap, and the sealant 13 can withstand greater pressure after curing.
  • the sealant 13 can support the outer sheath 20, so that the force on the outer sheath 20 is balanced inside and outside, and the micro-cable will not be deformed or the deformation will be small .
  • the outer sheath 20 even if there are micropores on the surface of the outer sheath 20, after the gas outside the outer sheath 20 enters the area surrounded by the outer sheath 20 along the micropores, the gas cannot continue to flow in the sealant 13 because there is no gap in this area. Movement, the outer sheath 20 will not bulge and burst, thereby reducing the damage to the performance of the microcable during the process of blowing the microcable into the sub-pipe.
  • the microcable provided by the embodiment of the present application includes a cable core 10 , the cable core 10 is circular, and the cable core 10 includes a central strength member 12 .
  • the central reinforcement 12 By arranging the central reinforcement 12, the tensile capacity of the microcable can be improved.
  • the central reinforcement 12 is a glass fiber reinforced plastic rod, with an elastic modulus ⁇ 52GPa and a tensile strength ⁇ 1100Mpa. In this way, the central reinforcement 12 has higher rigidity and tensile capacity, and the adhesive force between the central reinforcement 12 and the sealant 13 is relatively large.
  • the microcable provided in the embodiment of the present application also includes multiple optical units 11 twisted around the central strength member 12.
  • the twisting method of the multiple optical units 11 can be unidirectional S twisting, and the twisting pitch is 100 mm to 500 mm.
  • the pay-off tension of the optical unit 11 during twisting is 3N-5N, and the diameter of the optical unit 11 and the diameter of the central reinforcing member 12 may be the same or different.
  • the diameter of the optical unit 11 is the same as that of the central strengthening member 12 , so that the roundness of the cable core 10 formed by twisting a plurality of optical units 11 around the central strengthening member 12 can be improved.
  • the number of optical units 11 of each micro-cable can be set according to the capacity requirement of the micro-cable to transmit data. Exemplarily, the number of light units 11 is 6-24. Referring to FIG. 1 , in a specific implementation manner, there is one central reinforcing member 12 and six light units 11 .
  • Each optical unit 11 includes an optical fiber bundle, the optical fiber bundle is circular, and the optical fiber bundle includes a cured resin 112 and a plurality of optical fibers 111 distributed in the cured resin 112 in a bundle shape at intervals.
  • the optical fiber 111 will not move relative to the cured resin 112 when the micro cable is laid by air blowing, and the performance stability of the micro cable is better; while in the related art, the optical fiber is arranged in the ointment, due to the oil
  • the paste has flowability. When the microcable is laid by air blowing, the optical fiber will move relative to the paste, and the performance stability of the microcable is poor.
  • the curing resin 112 is a thermosetting resin
  • the viscosity of the thermosetting resin is 3000mPa ⁇ S-4500mPa ⁇ S at 25°C before curing
  • the hardness (HA) after curing is about 20-35, so as to ensure that the cured optical fiber
  • the bundle has certain viscoelasticity and flexibility, and does not affect the transmission performance of the optical fiber 111.
  • thermosetting resin In terms of parts by weight, the components in the thermosetting resin are as follows: acrylate monomer: 75-88 parts by weight; silicon dioxide superfine powder treated with a silane coupling agent: 3-5 parts by weight; thermosetting accelerator Agent melamine: 3-5 parts by weight; aromatic hydrocarbon solvent: 1-5 parts by weight; second polymer additive: 5-10 parts.
  • the second polymer additive includes at least one of ethylene glycol, propylene glycol, benzyl ester, adipate, and phthalate.
  • the curable resin 112 is a photocurable resin
  • the viscosity of the photocurable resin is 4000mPa ⁇ S-5500mPa ⁇ S at 25°C before curing, and the density is 1.10g/cm 3 to 1.13g/cm 3
  • the photocurable resin The hardness (HD) after curing is about 55-77
  • the elastic modulus of the light-curing resin after curing is 400MPa-800MPa at 2.5% elastic mass and 23°C, and the elongation at break is ⁇ 40%.
  • the material of the photocurable resin includes a base resin, a photosensitizer, an active agent and other polymer additives, wherein the photosensitizer and the active agent are uniformly mixed in the base resin.
  • the photocurable resin can initiate a polymerization reaction by a photosensitizer under ultraviolet light irradiation, so that the photocurable resin is coated on the outside of the optical fiber to form a circular cured optical fiber bundle.
  • the base resin is a polyacrylic resin
  • the photosensitizer is an ultraviolet photoinitiator
  • the active agent is an ultraviolet photoactive curing agent.
  • the components in the photocurable resin are as follows: polyacrylic acid resin: 85-92 parts by weight; UV active curing agent: 2-5 parts by weight; UV photoinitiator: 4-8 parts by weight; antioxidant : 1-2 parts by weight; the third polymer additive: 1-3 parts by weight.
  • the third polymer additive includes at least one of isopropanol, n-butanol, methyl salicylate, oxalamide, and benzoate.
  • the optical unit 11 when the curing resin 112 is a thermosetting resin, since the hardness of the thermosetting resin is relatively small after curing, in order to improve the anti-deformation capability of the optical unit 11, the optical unit 11 also includes a secondary coating layer covering the outer peripheral surface of the optical fiber bundle 113.
  • the cured resin 112 is a light-cured resin, since the cured light-cured resin has a higher hardness, it is not necessary to extrude the secondary coating layer 113 on the outer peripheral surface of the optical fiber bundle, thereby simplifying the process flow.
  • the material of the secondary covering layer 113 is polybutylene terephthalate, and the thickness of the secondary covering layer 113 is 0.1 mm ⁇ 0.3 mm.
  • the material of the secondary coating layer 113 can also be thermoplastic polymers such as nylon, polycarbonate, thermoplastic polyester elastomer (TPU, TPEE).
  • the secondary coating layer 113 can be formed on the outer peripheral surface of the optical fiber bundle by extrusion molding. Since the secondary coating layer 113 and the cured resin 112 are both polymer materials, they can be tightly combined and can be installed in air blowing. During the process of the micro-cable, even if the micro-cable is subjected to high gas pressure, the optical fiber bundle and the secondary coating layer 113 will not slip, thereby improving the airtightness and water resistance of the optical unit 11 . And the surface structure of the secondary coating layer 113 can be controlled by the mold, so that the surface of the light unit 11 is smooth and round.
  • the optical fibers 111 in the optical fiber bundle may be different types of optical fibers such as G.652 optical fibers and G.657 optical fibers.
  • the optical fiber 111 is a G.652 optical fiber.
  • the optical fiber 111 includes a core and a coating layer.
  • the core is located in the coating layer.
  • the coating layer can directly coat the outer peripheral surface of the fiber core, or be coated with an intermediate layer such as a silica glass cladding on the outer peripheral surface of the fiber core.
  • the cladding layer covers the outer peripheral surface of the outermost intermediate layer.
  • the optical fiber 111 is a colored optical fiber, and the coloring colors of the optical fiber 111 include blue, orange, green, brown, gray, white, red, black, yellow, purple, pink, and turquoise. Using colored optical fibers is beneficial to distinguish different optical fibers.
  • the optical fiber 111 can be a smaller-sized optical fiber with a coating diameter of 180 ⁇ m-200 ⁇ m, or a larger-sized optical fiber with a coating diameter of 245 ⁇ m-255 ⁇ m.
  • the diameter of the coating layer of the optical fiber 111 is 245 ⁇ m ⁇ 255 ⁇ m.
  • each optical fiber bundle can be set according to the capacity requirement of the microcable to transmit data.
  • each optical fiber bundle includes 1-24 optical fibers 111
  • the total number of optical fibers in the microcable may be 12-576
  • the plurality of optical fibers 111 in the optical fiber bundle are distributed in a bundle shape at intervals.
  • optical unit 11 with 12 cores and 24 cores is taken as an example below to further introduce the size of the optical unit 11, wherein 12 cores means that the optical unit 11 includes 12 optical fibers 111, and 24 cores means that the optical unit 11 includes 24 optical fibers. 111.
  • the optical unit 11 When the optical unit 11 has 12 cores and the cured resin 112 is a thermosetting resin, the optical unit 11 also includes a secondary coating layer 113 covering the outer peripheral surface of the optical fiber bundle.
  • the diameter of the optical unit 11 is 1.3 mm to 1.7 mm.
  • the diameter of the secondary covering layer 113 is 0.9 mm to 1.2 mm, and the thickness of the secondary coating layer 113 is 0.1 mm to 0.3 mm.
  • the optical unit 11 When the optical unit 11 has 24 cores and the cured resin 112 is a thermosetting resin, the optical unit 11 also includes a secondary coating layer 113 covering the outer peripheral surface of the optical fiber bundle.
  • the diameter of the optical unit 11 is 1.6 mm to 2.3 mm.
  • the diameter of the secondary covering layer 113 is 1.4 mm to 1.7 mm, and the thickness of the secondary coating layer 113 is 0.1 mm to 0.3 mm.
  • the optical unit 11 has 12 cores and the cured resin 112 is a light-cured resin, there is no need to arrange a secondary coating 113 outside the optical fiber bundle, and the diameter of the optical fiber bundle is the diameter of the optical unit 11, and the diameter of the optical fiber bundle is 1.0mm ⁇ 1.5mm.
  • the diameter of the optical fiber bundle is the diameter of the optical unit 11, and the diameter of the optical bundle is 1.5 mm to 1.5 mm. 2.0mm.
  • the cable core 10 provided by the embodiment of the present application further includes a sealant 13 filled in the stranding gaps of multiple optical units 11 , and the sealant 13 can be filled by a pneumatic pressure filling device.
  • the sealant 13 can fill the twisted gaps of multiple optical units 11, and the sealant 13 can be bonded with the optical unit 11, the outer sheath 20, and the central reinforcement 12, so that the outer sheath 20 will not surround gaps in the area.
  • the sealant 13 can withstand relatively high pressure after being cured.
  • the sealant 13 can support the outer sheath 20, so that the force on the inside and outside of the outer sheath 20 is balanced, and the micro-cable will not be deformed.
  • the gas cannot continue to flow in the sealant 13 because there is no gap in this area. Movement, the outer sheath 20 will not bulge and burst, thus ensuring the normal operation of the micro-cable.
  • the sealant 13 also has the function of water resistance and water resistance, thereby realizing the water resistance and sealing of the entire section of the micro-cable, so that the micro-cable can be laid underwater.
  • the sealant 13 can be a one-component room temperature cross-linking compound or a two-component room temperature cross-linking compound, which has excellent thixotropy and room temperature cold filling performance, and no shrinkage after curing.
  • the sealant 13 is a one-component room-temperature cross-linking compound, including an active resin, a thickener and a tackifier, wherein the thickener and the tackifier are uniformly mixed in the active resin. In the actual manufacturing process, the thickener and tackifier can be uniformly mixed in the active resin through a homogenization process.
  • the above two-component room temperature cross-linking compound can be obtained by mixing two different one-component room temperature cross-linking compounds according to the required ratio.
  • the above-mentioned one-component and two-component can be understood as types of active resins.
  • the active resin is polymer polyacrylic resin
  • the tackifier is binary ethylene propylene rubber
  • the thickener is fumed silica.
  • the components in the sealant 13 are as follows: polymer polyacrylic resin: 15-35 parts by weight; basic synthetic polyolefin oil: 45-60 parts by weight, binary ethylene-propylene rubber: 5-10 parts by weight, Fumed silica: 5-10 parts by weight; antioxidant: 1-3 parts by weight; dispersant: 1-3 parts by weight; water blocking agent: 3-5 parts by weight; first polymer additive: 3-5 parts by weight parts by weight.
  • the first polymer additive includes at least one of azelate, benzoate, epoxy fatty acid ester, polybutadiene, N-methylol acrylamide, and hydroxyethyl methacrylate.
  • the sealant 13 is cured to form a deformable rubber body with a hardness of 35HA-45HA and a cured density of 1.2g/cm 3 -1.4g/cm 3 .
  • the rubber body can absorb part of the impact force, thereby protecting the structure of the cable core 10 and ensuring the normal operation of the microcable.
  • the sealant 13 after the sealant 13 is cured, it also has the characteristics of water pressure resistance, non-sticky, easy to peel, good flexibility, can be bonded with nylon, polyurethane materials and the central reinforcement 12, has good compatibility with microcable materials, and has good sealing performance. Features such as high water resistance.
  • the micro-cable will not be greatly deformed during the air blowing laying process, thereby ensuring the normal operation of the micro-cable.
  • the use temperature of the sealant 13 after curing is between -60°C and 220°C.
  • the microcable provided by the embodiment of the present application further includes an outer sheath 20 covering the outer peripheral surface of the cable core 10 .
  • the outer sheath 20 can protect the structure of the cable core 10 and improve the mechanical strength of the microcable.
  • the material of the outer sheath 20 is at least one of polyurethane elastomer, polyvinyl chloride, thermoplastic elastomer, and thermoplastic polyester elastomer.
  • the outer sheath 20 can be glued with the sealant, thereby preventing the cable core 10 from contacting the outer sheath. 20 gaps are created.
  • the outer sheath 20 can be formed by extrusion molding. Specifically, the extrusion mold used when extruding the outer sheath 20 is an extrusion mold. This arrangement can make the combination of the cable core 10 and the outer sheath 20 more efficient. Tight, so that the micro-cable structure is tighter and the appearance is smoother.
  • microcables provided by the embodiments of the present application do not need to be filled with ointment during the production process, and are of a fully dry structure.
  • the pollution is small, and it is conducive to the connection of optical fibers, and the construction is more convenient.
  • the longitudinal watertightness of the microcable provided by the embodiment of the present application satisfies the water pressure of 1MPa-4MPa, no water leakage, and the cable core 10 does not slip relative to the outer sheath 20 .
  • the airtightness of the microcable provided by the embodiment of the present application satisfies the air pressure of 0 to 10 Bar, and the cable core 10 does not significantly slip relative to the outer sheath 20, and the outer sheath
  • the sheath 20 does not crack, or even if a crack exists on the surface of the outer sheath 20 itself, the crack does not grow.
  • the 72-core microcable refers to a microcable including 72 optical fibers 111 .
  • the 72-core microcable includes a cable core 10 and an outer sheath 20 covering the cable core 10.
  • the cable core 10 includes a central strength member 12 and 6 optical units 11, and the 6 optical units 11 wrap around The central stiffener 12 is stranded.
  • Each optical unit 11 includes an optical fiber bundle and a secondary coating layer 113
  • the optical fiber bundle includes thermosetting resin and 12 optical fibers 111 with a coating diameter of about 245 ⁇ m to 255 ⁇ m
  • the secondary coating layer 113 is coated on the outer peripheral surface of the optical fiber bundle Butylene terephthalate composition.
  • the diameter of the 12-core optical fiber bundle is 0.9 mm to 1.2 mm
  • the diameter of the optical unit 11 is 1.3 mm to 1.7 mm
  • the thickness of the secondary coating layer 113 is 0.1 mm to 0.3 mm.
  • the central reinforcement is a glass fiber reinforced plastic rod with an elastic modulus of ⁇ 52GPa and a tensile strength of ⁇ 1100Mpa.
  • the diameter of the central reinforcement 12 is consistent with the diameter of the light unit 11 to ensure the roundness of the cable core 10 after stranding.
  • the twisted gaps of the plurality of optical units 11 are filled with sealant 13 , and the sealant 13 has the functions of sealing and water resistance.
  • the size of the cable core 10 of the 72-core micro-cable is 4.2 mm to 5.1 mm
  • the outer sheath 20 is made of polyurethane elastomer material
  • the thickness of the outer sheath 20 is 0.4 mm to 0.8 mm
  • the diameter of the 72-core micro cable is 5.0 mm to 6.6 mm .
  • a certain number of filling elements can also be used to replace part of the optical units 11 according to the transmission capacity requirements of the microcable, so that the total number of cores of the microcable ranges from 12 cores to 72 cores.
  • 72-core micro-cable if the transmission capacity requirement of the micro-cable is small and only 4 optical units 11 are needed to meet the demand, then 2 filling elements can be used to replace the 2 redundant optical units 11, thereby reducing The cost of the small micro-cable, at this time the micro-cable is a 48-core micro-cable.
  • the number of optical units 11 of the microcable can be 6 to 24, the number of cores of each optical unit 11 can be 4 cores to 24 cores, and the total number of cores of the microcable can be 12 cores to 576 cores, so that in a certain range The transmission capacity of the micro-cable can be flexibly adjusted within the system.
  • the embodiment of the present application also provides a filling device, which can be used to fill the sealant 13 in the twisted gaps of the multiple optical units 11 in the above embodiment.
  • the filling device includes a glue injection and line mold 30, a glue injection valve 40, a sealant pump 50, and an air source 60.
  • the glue injection and line mold 30 is provided with a filling channel 31 and an injection mold. Glue channel 32.
  • the glue injection and line mold 30 includes an upper mold and a lower mold, the lower end of the upper mold is provided with a first channel, and the upper end of the lower mold is provided with a second channel, when the lower end of the upper mold is attached to the upper end of the lower mold At this time, the first channel and the second channel jointly form a filling channel 31, and a glue injection channel 32 communicating with the filling channel 31 is also formed in the upper mold.
  • the filling channel 31 includes a filling inlet and a filling outlet.
  • the central reinforcement 12 and the plurality of optical units 11 pass through the filling channel 31 from the filling inlet, pass out of the filling channel 31 from the filling outlet, and enter the twisted gaps of the plurality of optical units 11 Fill the sealant 13; one end of the injection channel 32 communicates with the injection valve 40, specifically, one end of the injection channel 32 communicates with the nozzle of the injection valve 40, and the other end communicates with the filling channel 31; the sealant pump 50 and The air sources 60 are all communicated with the injection valve 40;
  • the sealant pump 50 is used to pump the sealant 13 into the glue injection valve 40; the air source 60 is used to adjust the air pressure in the glue injection valve 40 to control the glue discharge speed of the glue injection valve 40; Sealant 13 is filled in the stranding gaps of the plurality of optical units 11 .
  • the central reinforcing member 12 and multiple light units 11 are passed through the filling channel 31 and move along the length direction of the filling channel 31, while the multiple optical units 11 are twisted around the central reinforcing member 12.
  • the sealant 13 flowing out from the glue injection valve 40 passes through the glue injection channel 32 and the filling channel 31 and then fills in the stranding gaps of the plurality of optical units 11 .
  • the central strength member 12 and the plurality of optical units 11 can preliminarily form the cable core 10 after being twisted and filled.
  • the filling device provided in the embodiment of the present application adjusts the air pressure in the glue injection valve 40 through the air source 60, thereby controlling the glue discharge speed of the glue injection valve 40, ensuring that the sealant 13 can be completely filled in the gap of the cable core 10, and improving the Performance of the cable core 10.
  • a wire passing die is also provided at the filling outlet, and the size of the wire passing die can be designed according to the size of the cable core 10 . Excess sealant on the surface of the cable core 10 can be removed by passing through the wire mold. In addition, the cable core 10 after passing through the wire mold can also be drawn into the heating device to accelerate the curing process of the sealant 13 .
  • the embodiment of the present application also provides a method for manufacturing a microcable, including:
  • the optical fiber is a colored optical fiber
  • the colored colors of the optical fiber include blue, orange, green, brown, gray, white, red, black, yellow, purple, pink, and turquoise.
  • the use of colored optical fibers is beneficial to different fiber optics.
  • the tension when the optical fibers are unwound can be a constant tension between 50N and 80N.
  • the outer sheath is extruded on the outer peripheral surface of the cable core, and the outer sheath and the cable core together form a microcable. Specifically, the outer sheath is extruded on the outer peripheral surface of the cable core by using a second extrusion mold, and the second extrusion mold is an extrusion mold.
  • the doubling mold, coating mold, curing device and extrusion mold can be set on the same horizontal line, which is beneficial to ensure consistent tension of optical fiber pay-off and reduce the attenuation coefficient of optical fiber.
  • the step of extruding a secondary coating layer on the outer peripheral surface of the cured optical fiber bundle includes:
  • the vacuum treatment can be performed by using a vacuum machine, and the degree of tightness between the secondary coating layer and the cured optical fiber bundle can be controlled by the degree of vacuum displayed by the vacuum machine.
  • Such setting can ensure good air tightness and water resistance between the secondary coating layer of the optical fiber and the optical fiber bundle by adjusting the vacuum pressure, so that the surface of the optical unit is smooth and the appearance is round.
  • the filling device in the above embodiment can be used, and the plurality of optical units are twisted
  • the timely pay-off tension is controlled between 3N and 5N.
  • the central reinforcing member and multiple optical units are passed through the filling channel, and the central reinforcing member and the multiple optical units are moved along the length direction of the filling channel, and at the same time, the multiple optical units are twisted around the central reinforcing member,
  • the sealant flowing out from the injection valve passes through the injection channel, fills the channel, and then fills the stranding gaps of multiple optical units.
  • the central strength member and multiple optical units can preliminarily form a cable core after being twisted and filled.
  • the preliminarily formed cable core can remove excess sealant on the surface of the cable core after passing through the wire mold at the filling outlet of the filling hole, so as to improve the roundness of the cable core.
  • the microcable manufacturing method provided in this embodiment can adjust the air pressure in the glue injection valve through the air source, so as to ensure that the sealant can be completely filled in the twisted gaps of multiple optical units, improving the performance of the microcable.
  • a step of sending the cable core into a heating device is further included, so as to accelerate the curing of the cable core.
  • the structures and materials of the microcables in the above method embodiments can refer to the above product embodiments, and will not be repeated here.

Abstract

一种微缆及其制造方法、填充装置，微缆用于传输信号，涉及微缆技术领域。微缆包括缆芯（10）和包覆缆芯（10）外周面的外护套（20），缆芯（10）包括中心加强件（12）、多根光单元（11）以及密封胶（13），多根光单元（11）绕中心加强件（12）绞合，密封胶（13）填充于多根光单元（10）的绞合缝隙内。还提供了微缆的制造方法。该微缆解决了在将微缆吹入子管的过程中，微缆容易发生形变，损坏微缆的性能的技术问题。填充装置包括注胶并线模（30）、注胶阀（40）、密封胶泵（50）以及气源（60），注胶并线模（30）内设置有填充通道（31）和注胶通道（32）。

Description

微缆及其制造方法、填充装置
本申请要求于2021年6月17日提交中国专利局、申请号为202110674719.3、申请名称为“微缆及其制造方法、填充装置”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及微缆技术领域，尤其涉及一种微缆及其制造方法、填充装置。
背景技术
微缆又称为微型光缆，通常在光性能相同的情况下，微缆比同芯数的传统光缆外径小、重量轻，因此，微型光缆得到越来越广泛的使用。
微缆可以采用气吹敷设，在微缆的气吹敷设过程中，首先利用压缩空气将子管吹入已敷设好的母管中，然后根据发展需求，利用压缩空气分批次地将微缆吹入子管中。其中，母管通常为硅芯管，子管通常为高密度聚乙烯管，母管与子管可用于保护微缆。通过气吹敷设的方式，可以简化施工流程，且节约施工成本。
然而，在将微缆吹入子管的过程中，微缆容易发生形变，损坏微缆的性能。
发明内容
本申请的目的在于提供一种微缆及其制造方法、填充装置，用于在将微缆吹入子管的过程中，减小对微缆性能的损害。
第一方面，本申请公开了一种微缆，所述微缆包括缆芯和包覆所述缆芯外周面的外护套，所述缆芯包括中心加强件、多根光单元以及密封胶，多根所述光单元绕所述中心加强件绞合，所述密封胶填充于多根所述光单元的绞合缝隙内。
基于上述技术内容，本申请公开的微缆包括缆芯和外护套，外护套包覆在缆芯外周面上，缆芯包括中心加强件以及多根绕中心加强件绞合的光单元，多根光单元的绞合缝隙内填充有密封胶。密封胶可以充满光单元的绞合缝隙，并且密封胶可以与光单元、外护套等部位粘合，不会在外护套包围的区域内留下缝隙。外护套包围的区域内没有缝隙，也就不会产生内外气体压力差，并且密封胶固化后可以承受较大的压力，在气吹敷设微缆时，可以保持外护套内外的受力平衡，微缆不会发生变形或形变量很小，从而在将微缆吹入子管的过程中，减小了对微缆性能的损害。
可选的，所述密封胶的材质包括活性树脂、增稠剂以及增粘剂，其中，所述增稠剂和所述增粘剂均匀的混合在所述活性树脂中。
可选的，所述密封胶固化后的硬度为35HA～45HA，所述密封胶固化后的密度为1.2g/cm 3～1.4g/cm 3。
可选的，所述光单元包括光纤束，所述光纤束包括多根光纤和固化树脂，多根所述光纤呈束状间隔分布在所述固化树脂内部。
可选的，所述固化树脂为热固化树脂；所述光单元还包括包覆所述光纤束外周面的二 次被覆层，所述二次被覆层的材质包括聚对苯二甲酸丁二醇酯，且所述二次被覆层的厚度为0.1mm～0.3mm。
可选的，每根所述光纤束中的光纤数量为12根或24根；
当每根所述光纤束中的光纤数量为12根时，所述光纤束的直径为0.9mm～1.2mm，所述光单元的直径为1.3mm～1.7mm；
当每根所述光纤束中的光纤数量为24根时，所述光纤束的直径为1.4mm～1.7mm，所述光单元的直径为1.6mm～2.3mm。
可选的，所述固化树脂为光固化树脂，所述光固化树脂包括基础树脂、光敏剂以及活性剂，其中，所述光敏剂与所述活性剂均匀混合在所述基础树脂中。
可选的，每根所述光纤束中的光纤数量为12根或24根；
当每根所述光纤束中的光纤数量为12根时，所述光纤束的直径为1.0mm～1.5mm；
当每根所述光纤束中的光纤数量为24根时，所述光纤束的直径为1.5mm～2.0mm。
可选的，所述外护套的材质为聚氨酯弹性体、聚氯乙烯、热塑性弹性体、热塑性聚酯弹性体中的至少一种；所述外护套的厚度为0.4mm～0.8mm。
第二方面，本申请公开了一种填充装置，所述填充装置包括注胶并线模、注胶阀、密封胶泵以及气源，所述注胶并线模内设置有填充通道和注胶通道，
所述填充通道包括填充入口与填充出口，中心加强件与多根光单元从所述填充入口穿入所述填充通道，从所述填充出口穿出所述填充通道；所述注胶通道的一端与所述注胶阀连通，另一端与所述填充通道连通；所述密封胶泵和所述气源均与所述注胶阀连通；
所述密封胶泵用于向所述注胶阀内泵注密封胶；所述气源用于调节所述注胶阀内的气压大小，以控制所述注胶阀的出胶速度；所述填充通道用于向多个所述光单元的绞合缝隙内填充所述密封胶。
基于上述技术内容，本申请公开的填充装置通过密封胶泵将密封胶泵入注胶阀中，通过气源控制注胶阀的出胶速度，注胶阀将密封胶注入密封通道中，密封胶经过密封通道与填充通道最终填充在位于填充通道内的光单元的绞合缝隙中。这样设置，由于注胶阀的出胶速度可以调控，从而可以保证密封胶充分填充在多根光单元的绞合缝隙中，提高了缆芯的气密性。
第三方面，本申请公开了一种微缆的制造方法，所述微缆的制造方法包括：
提供中心加强件与多根光纤；
对多根所述光纤均匀放线，使多根所述光纤经过并线模具，以使多根所述光纤呈束状间隔排布；
将呈束状间隔排布的多根所述光纤牵引至涂覆模具中，使多根所述光纤呈束状间隔分布在固化树脂内部，形成未固化的光纤束；
使未固化的光纤束经过固化装置，形成固化后的光纤束；
将固化后的光纤束牵引至第一挤塑模具中，在固化后的光纤束外周面挤塑二次被覆层；固化后的光纤束与二次被覆层共同形成光单元；
将多个所述光单元绕所述中心加强件绞合，并在多个所述光单元的绞合缝隙内填充密封胶；所述中心加强件、多个所述光单元以及所述密封胶共同形成缆芯；
在所述缆芯外周面挤塑外护套，所述外护套与所述缆芯共同形成微缆。
基于上述技术内容，本申请公开的微缆的制造方法包括提供中心加强件与多根光纤；对多根光纤均匀放线，使多根光纤经过并线模具，以使多根光纤呈束状间隔排布；将呈束状间隔排布的多根光纤牵引至涂覆模具中，使多根光纤呈束状间隔分布在固化树脂内部，形成未固化的光纤束；使未固化的光纤束经过固化装置，形成固化后的光纤束；将固化后的光纤束牵引至第一挤塑模具中，在固化后的光纤束外周面挤塑二次被覆层；固化后的光纤束与二次被覆层共同形成光单元；将多根光单元绕中心加强件绞合，并在多根光单元的绞合缝隙内填充密封胶；中心加强件、多根光单元以及密封胶共同形成缆芯；在缆芯外周面挤塑外护套，外护套与缆芯共同形成微缆。经过上述步骤形成的微缆中的密封胶可以充满多根光单元的绞合缝隙，并且密封胶可以与光单元、外护套等部位粘合，不会在外护套包围的区域内留下缝隙。外护套包围的区域内没有缝隙，也就不会产生内外气体压力差，并且密封胶固化后可以承受较大的压力，在气吹敷设微缆时，可以保持外护套内外的受力平衡，微缆不会发生变形或形变量很小，从而在将上述步骤中制造的微缆吹入子管的过程中，微缆受到的损害较小。
可选的，将固化后的光纤束牵引至挤塑模具中，在固化后的光纤束外周面形成二次被覆层的步骤包括：
对所述挤塑模具的挤塑通道进行抽真空处理，以控制所述二次被覆层与所述固化后的光纤束之间的松紧程度。
可选的，将多个所述光单元绕所述中心加强件绞合，并在多个所述光单元的绞合缝隙内填充密封胶的步骤中，采用如上所述的填充装置。
附图说明
图1为本申请实施例提供的微缆的结构示意图；
图2为本申请实施例提供的缆芯的结构示意图；
图3为本申请实施例提供的填充装置的结构示意图。
附图标记说明：
10：缆芯；                11：光单元；
111：光纤；               112：固化树脂；
113：二次被覆层；         12：中心加强件；
13：密封胶；              20：外护套；
30：注胶并线模；          31：填充通道；
32：注胶通道；            40：注胶阀；
50：密封胶泵；            60：气源。
具体实施方式
相关技术中，微缆包括缆芯和包覆在缆芯外的外护套，缆芯包括多根相绞合的光单元，多根光单元的绞合缝隙中的填充有多根阻水纱，多根阻水纱之间存在缝隙，且阻水纱与光单元以及外护套之间也存在缝隙，导致外护套包围的区域内存在缝隙。气吹敷设微缆时，微缆的外护套外部收到较大的气体压力，而外护套包围的区域内的缝隙中的气体压力较小，外护套内外的气体产生压力差，造成微缆变形。此外，在实际气吹敷设的过程中，外护套 的护套表面可能存在微孔，使得外护套外的气体顺着微孔进入外护套包围的区域内，并沿着外护套包围的区域内的缝隙运动，最终导致外护套出现鼓包甚至爆裂，损坏微缆的性能。
针对上述问题，本申请实施例提供的微缆在多根光单元的绞合缝隙内填充密封胶，密封胶可以充满光单元的绞合缝隙，并且密封胶可以与光单元、外护套等部位粘合，从而不会在外护套包围的区域内留下缝隙。气吹敷设微缆时，外护套包围的区域内没有气体，也就不会产生内外气体压力差，并且密封胶固化后可以承受较大的压力，即使密封胶内存在气泡之类的结构，仍然可以保持外护套内外的受力平衡，微缆不会发生形变或形变较小。此外，即使外护套的护套表面可能存在微孔，由于外护套包围的区域内没有留下缝隙，外护套外的气体顺着微孔进入外护套包围的区域内之后也无法继续运动，外护套不会出现鼓包与爆裂的情况，从而在将微缆吹入子管的过程中，减小了对微缆性能的损害。
为了使本申请实施例的上述目的、特征和优点能够更加明显易懂，下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述。显然，所描述的实施例仅仅是本申请的一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有作出创造性劳动的前提下所获得的所有其它实施例，均属于本申请保护的范围。
如图1和图2所示，本申请实施例提供了一种微缆，包括缆芯10和包覆缆芯10外周面的外护套20，缆芯10包括中心加强件12、多根光单元11以及密封胶13，多根光单元11绕中心加强件12绞合，密封胶13填充于多根光单元11的绞合缝隙内。
这样设置，密封胶13可以充满多根光单元11的绞合缝隙，并且密封胶13可以与光单元11、外护套20等部位粘合，从而不会在外护套20包围的区域内留下缝隙，并且密封胶13固化后可以承受较大的压力。当气吹敷设微缆使得外护套20外受到较大的气体压力时，密封胶13可以支撑外护套20，使外护套20内外受力平衡，微缆不会发生形变或形变较小。此外，即使外护套20的表面存在微孔，外护套20外的气体顺着微孔进入外护套20包围的区域之后，由于该区域内没有缝隙，气体也无法继续在密封胶13中运动，外护套20不会出现鼓包与爆裂的情况，从而在将微缆吹入子管的过程中，减小了对微缆性能的损害。
如图1所示，本申请实施例提供的微缆包括缆芯10，缆芯10为圆形，缆芯10包括中心加强件12。通过设置中心加强件12，可以提高微缆的抗拉能力。
在一种具体的实施例中，中心加强件12为玻璃纤维增强塑料杆，弹性模量≥52GPa，拉伸强度≥1100Mpa。这样设置，中心加强件12具有较高的刚度与抗拉能力，且中心加强件12与密封胶13之间的粘合力较大。
本申请实施例提供的微缆还包括绕中心加强件12绞合的多根光单元11，多根光单元11的绞合方式可以为单向S绞合，绞合节距为100mm～500mm，且光单元11绞合时的放线张力为3N～5N，光单元11的直径与中心加强件12的直径可以相同也可以不同。在本实施例中，光单元11的直径与中心加强件12的直径相同，这样设置，可以提高多根光单元11绕中心加强件12绞合后形成的缆芯10的圆整度。
每根微缆的光单元11的数量可以根据微缆传输数据的容量需求进行设置。示例性的，光单元11的数量为6根～24根。参照图1，在一种具体的实施方式中，中心加强件12的数量为1根，光单元11的数量为6根。
每根光单元11包括光纤束，光纤束为圆形，光纤束包括固化树脂112和呈束状间隔分 布在固化树脂112中的多根光纤111。这样设置，在固化树脂112固化后，气吹敷设微缆时光纤111相对固化树脂112不会发生相对移动，微缆性能稳定性较好；而相关技术中将光纤设置在油膏中，由于油膏具有可流动性，气吹敷设微缆时，光纤相对油膏会发生移动，微缆性能稳定性较差。
在一些实施方式中，固化树脂112为热固化树脂，热固化树脂固化前25℃下粘度为3000mPa·S～4500mPa·S，固化后硬度(HA)在20～35左右，从而保证固化后的光纤束具有一定的粘弹性和柔韧性，且不影响光纤111的传输性能。
按重量份计，热固化树脂中各组分如下：丙烯酸酯类单体：75～88重量份；经硅烷偶联剂表面处理的二氧化硅超细粉末：3～5重量份；热固化促进剂三聚氰胺：3～5重量份；芳香烃溶剂：1～5重量份；第二高分子助剂：5～10份。其中，第二高分子助剂包括乙二醇、丙二醇、笨甲酸脂、已二酸酯、邻苯二甲酸酯中的至少一种。
在另一些实施方式中，固化树脂112为光固化树脂，光固化树脂固化前25℃下粘度为4000mPa·S～5500mPa·S，密度在1.10g/cm 3～1.13g/cm 3；光固化树脂固化后硬度(HD)在55～77左右；光固化树脂固化后在2.5％弹性量、23℃下的弹性模量在400MPa～800MPa，断裂伸长率≥40％。
光固化树脂的材质包括基础树脂、光敏剂、活性剂以及其他高分子助剂，其中，光敏剂与活性剂均匀混合在基础树脂中。光固化树脂能在紫外光照射下由光敏剂引发聚合反应，使光固化树脂包覆在光纤外，形成圆形的固化光纤束。示例性的，基础树脂为聚丙烯酸树脂，光敏剂为紫外光引发剂，活性剂为紫外光活性固化剂。按重量份计，光固化树脂中各组分如下：包括聚丙烯酸树脂：85～92重量份；紫外光活性固化剂：2～5重量份；紫外光引发剂：4～8重量份；抗氧化剂：1～2重量份；第三高分子助剂：1～3重量份。其中，第三高分子助剂包括异丙醇、正丁醇、水杨酸甲脂、乙二酰二胺、苯甲酸脂的中的至少一种。
进一步的，当固化树脂112为热固化树脂时，由于热固化树脂固化后的硬度较小，为了提高光单元11的抗变形能力，光单元11还包括包覆光纤束外周面的二次被覆层113。而当固化树脂112为光固化树脂时，由于光固化树脂固化后的硬度较大，无需在光纤束的外周面挤塑二次被覆层113，从而精简了工艺流程。
在本实施例中，二次被覆层113的材质为聚对苯二甲酸丁二醇酯，二次被覆层113的厚度为0.1mm～0.3mm。在另一些实施例中，二次被覆层113的材质还可为尼龙、聚碳酸酯、热塑性聚酯弹性体(TPU、TPEE)等热塑性高分子聚合物。
在实际生产制造过程中，可以通过挤塑的方式在光纤束外周面形成二次被覆层113，由于二次被覆层113与固化树脂112均为高分子材料，可以紧密的结合，在气吹敷设微缆的过程中，即使微缆受到较大的气体压力，光纤束与二次被覆层113也不会发生滑移，从而提高光单元11的气密性与阻水性。并且可通过模具控制二次被覆层113的表面结构，使得光单元11表面光滑、圆整。
光纤束中的光纤111可以为G.652光纤、G.657光纤等不同种类的光纤。在本实施例中，光纤111为G.652光纤。光纤111包括纤芯和涂覆层，纤芯位于涂覆层内，涂覆层可以直接包覆纤芯的外周面，或者是在纤芯外周面包覆有硅玻璃包层等中间层，涂覆层包覆最外层的中间层外周面。
示例性的，光纤111为着色光纤，光纤111着色颜色包括蓝、橙、绿、棕、灰、白、 红、黑、黄、紫、粉红、青绿，采用着色光纤有利于不同光纤的区分。
光纤111可以为涂覆层直径在180μm～200μm的较小尺寸光纤，也可以为涂覆层直径在245μm～255μm的较大尺寸光纤。在本实施例中，光纤111的涂覆层直径为245μm～255μm。
每个光纤束中光纤111的数量可以根据微缆传输数据的容量需求进行设置。示例性的，每个光纤束包括1根～24根光纤111，微缆的总光纤数可以为12根～576根，光纤束中的多根光纤111呈束状间隔分布。
下面分别以12芯和24芯的光单元11为例，进一步介绍光单元11的尺寸大小，其中，12芯指光单元11中包括12根光纤111，24芯表示光单元11中包括24根光纤111。
当光单元11为12芯且固化树脂112为热固化树脂时，此时光单元11还包括包覆光纤束外周面的二次被覆层113，光单元11的直径为1.3mm～1.7mm，光纤束的直径为0.9mm～1.2mm，二次被覆层113的厚度为0.1mm～0.3mm。
当光单元11为24芯且固化树脂112为热固化树脂时，此时光单元11还包括包覆光纤束外周面的二次被覆层113，光单元11的直径为1.6mm～2.3mm，光纤束的直径为1.4mm～1.7mm，二次被覆层113的厚度为0.1mm～0.3mm。
当光单元11为12芯且固化树脂112为光固化树脂时，此时光纤束外无需设置二次被覆层113，光纤束的直径即为光单元11的直径，光纤束的直径为1.0mm～1.5mm。
当光单元11为24芯且固化树脂112为光固化树脂时，此时光纤束外无需设置二次被覆层113，光纤束的直径即为光单元11的直径，光线束的直径为1.5mm～2.0mm。
参照图1和图2，本申请实施例提供的缆芯10还包括填充在多根光单元11的绞合缝隙中的密封胶13，密封胶13可采用气动压力填充装置进行填充。这样设置，密封胶13可以充满多根光单元11的绞合缝隙，且密封胶13可以与光单元11、外护套20以及中心加强件12等部件粘合，从而不会在外护套20包围的区域内留下缝隙。并且密封胶13固化后可以承受较大的压力。当气吹敷设微缆使得外护套20外部受到较大的气体压力时，密封胶13可以支撑外护套20，使外护套20内外受力平衡，微缆不会发生变形。此外，即使外护套20的表面存在微孔，外护套20外的气体顺着微孔进入外护套20包围的区域之后，由于该区域内没有缝隙，气体也无法继续在密封胶13中运动，外护套20不会出现鼓包与爆裂的情况，从而保证微缆正常工作。
进一步的，密封胶13还具有抗水阻水的功能，从而实现了微缆的全截面阻水和密封，使得微缆能够敷设于水下。密封胶13可以为单组分的室温交联复合物或双组分的室温交联复合物，具有优异的触变性和室温冷填充性能，且固化后无收缩。在本实施例中，密封胶13为单组份的室温交联复合物，包括活性树脂、增稠剂以及增粘剂，其中，增稠剂和增粘剂均匀的混合在活性树脂中。在实际制造过程中，可以通过均化工艺将增稠剂和增粘剂均匀的混合在活性树脂中。
上述双组份的室温交联复合物可由两种不同的单组份室温交联复合物按照要求的比例混合得到。其中，上述单组份、双组分可以理解为活性树脂的种类。
在一种具体的实施例中，活性树脂为高分子聚丙烯酸树脂，增粘剂为二元乙丙橡胶，增稠剂为气相二氧化硅。按重量份计，密封胶13中各组分如下：高分子聚丙烯酸树脂：15～35重量份；基础合成聚烯烃油：45～60重量份，二元乙丙橡胶：5～10重量份，气相二氧化硅：5～10重量份；抗氧剂：1～3重量份；分散剂：1～3重量份；阻水剂：3～5重量份； 第一高分子助剂：3～5重量份。其中，第一高分子助剂包括壬二酸酯、苯甲酸脂、环氧脂肪酸酯、聚丁二烯、N-羟甲基丙烯酰胺、甲基丙烯酸羟乙酯中的至少一种。
在一些实施例中，密封胶13固化后形成一种可形变的橡胶体，硬度为35HA～45HA，固化后的密度为1.2g/cm 3～1.4g/cm 3，在气吹敷设微缆的过程中该橡胶体可以吸收部分冲击力，从而保护缆芯10的结构，保证微缆的正常工作。此外，密封胶13固化后还具有耐水压冲击、不粘手、易剥离、柔韧性好，能与尼龙、聚氨酯材料以及中心加强件12黏合、与微缆材料相容性良好，密封性好、高阻水性能等的特点。使微缆在气吹敷设过程中不会产生较大的形变，从而保证微缆的正常工作。示例性的，密封胶13固化后的使用温度在-60℃～220℃之间。
参照图1，本申请实施例提供的微缆还包括包覆缆芯10外周面的外护套20，外护套20可以保护缆芯10的结构，提高微缆的机械强度。
外护套20的材质为聚氨酯弹性体、聚氯乙烯、热塑性弹性体、热塑性聚酯弹性体中的至少一种，外护套20可以与密封胶沾粘，从而避免缆芯10与外护套20之间产生缝隙。可通过挤塑的方式形成外护套20，具体的，挤塑外护套20时采用的挤塑模具为挤压式模具，这样设置，可以使缆芯10与外护套20的结合更为紧密，从而使微缆结构更为紧密、外表更为平整。
本申请实施例提供的微缆在生产过程中无需填充油膏，为全干式结构，相比相关技术中填充有油膏的半干式结构微缆，本申请实施例提供的微缆对环境污染较小，且有利于光纤接续，施工更便捷。
进一步的，为了使微缆适应水下环境，本申请实施例提供的微缆纵向水密满足在1MPa～4MPa水压下，不漏水，且缆芯10相对于外护套20不发生滑移。且为了在气吹敷设过程中避免损坏微缆，本申请实施例提供的微缆气密性满足在0～10Bar的气压下，缆芯10相对于外护套20不发生明显滑移，外护套20不发生破裂，或者即使外护套20表面本身存在裂缝，该裂缝也不会扩大。
下面以本申请实施例提供的一种72芯微缆为例，具体介绍本申请实施例提供的微缆的结构。其中，72芯微缆指包括72根光纤111的微缆。如图1所示，该72芯微缆包括缆芯10和包覆在缆芯10外的外护套20，缆芯10包括中心加强件12以及6根光单元11，6根光单元11绕中心加强件12绞合。其中每根光单元11包括光纤束和二次被覆层113，光纤束包括热固化树脂和12根涂覆层直径在245μm～255μm左右的光纤111，二次被覆层113为在光纤束外周面被覆对苯二甲酸丁二醇酯构成。12芯光纤束的直径为0.9mm～1.2mm，光单元11的直径为1.3mm～1.7mm，二次被覆层113的厚度为0.1mm～0.3mm。中心加强件为玻璃纤维增强塑料杆，弹性模量≥52GPa，拉伸强度≥1100Mpa，中心加强件12的直径与光单元11直径一致，以保证绞合后缆芯10的圆整度。多根光单元11的绞合缝隙内填充有密封胶13，密封胶13具有密封功能与抗水阻水的功能。72芯微缆的缆芯10尺寸为4.2mm～5.1mm，外护套20采用聚氨酯弹性体材料，外护套20厚度为0.4mm～0.8mm，72芯微缆的直径为5.0mm～6.6mm。
在一些实施例中，还可以根据微缆的传输容量需求，采用一定数量的填充元件替代部分光单元11，使得微缆总芯数在12芯～72芯。以上述72芯微缆为例，如果微缆的传输容量需求较小，只需4根光单元11即可满足需求，则可以采用2根填充元件来替换2根多余 的光单元11，从而减小微缆的成本，此时微缆为48芯微缆。此外，微缆的光单元11可以为6根～24根，每根光单元11的芯数可为4芯～24芯，微缆的总芯数可为12芯～576芯，从而在一定范围内灵活调节微缆的传输容量。
本申请实施例还提供了一种填充装置，可用于在上述实施例中的多根光单元11的绞合缝隙中填充密封胶13。
如图3所示，本申请实施例提供的填充装置包括注胶并线模30、注胶阀40、密封胶泵50以及气源60，注胶并线模30内设置有填充通道31和注胶通道32。
进一步的，注胶并线模30包括上模具和下模具，上模具的下端设置有第一槽道，下模具的上端设置有第二槽道，当上模具的下端与下模具的上端贴合时，第一槽道与第二槽道共同形成填充通道31，上模具内还形成有与填充通道31连通的注胶通道32。
填充通道31包括填充入口与填充出口，中心加强件12与多根光单元11从填充入口穿入填充通道31，从填充出口穿出填充通道31，并在多根光单元11的绞合缝隙内填充密封胶13；注胶通道32的一端与注胶阀40连通，具体的，注胶通道32的一端与注胶阀40的枪嘴连通，另一端与填充通道31连通；密封胶泵50和气源60均与注胶阀40连通；
密封胶泵50用于向注胶阀40内泵注密封胶13；气源60用于调节注胶阀40内的气压大小，以控制注胶阀40的出胶速度；填充通道31用于向多根光单元11的绞合缝隙内填充密封胶13。
在实际填充时，中心加强件12与多根光单元11穿设在填充通道31内且沿填充通道31的长度方向运动，同时多根光单元11绕中心加强件12绞合，在绞合的过程中，从注胶阀40流出的密封胶13经过注胶通道32、填充通道31后填充于多根光单元11的绞合缝隙中。中心加强件12与多根光单元11在经过绞合与填充之后可以初步形成缆芯10。
本申请实施例提供的填充装置通过气源60调节注胶阀40内的气压大小，从而控制注胶阀40的出胶速度，确保密封胶13能够完全填充在缆芯10的缝隙中，提高了缆芯10的性能。
进一步的，填充出口处还设置有过线模，过线模的尺寸可以根据缆芯10的尺寸进行设计。通过过线模，可以将缆芯10表面多余的密封胶去除。此外，还可将经过过线模后的缆芯10牵引到加热装置内，以加速密封胶13的固化过程。
本申请实施例还提供了一种微缆的制造方法，包括：
提供中心加强件与多根光纤；其中，光纤为着色光纤，光纤着色颜色包括蓝、橙、绿、棕、灰、白、红、黑、黄、紫、粉红、青绿，采用着色光纤有利于不同光纤的区分。
对多根光纤均匀放线，使多根光纤经过并线模具，以使多根光纤呈束状间隔排布；光纤放线时的张力可以为在50N～80N之间的恒定张力。
将呈束状间隔排布的多根光纤牵引至涂覆模具，使多根光纤呈束状间隔分布在固化树脂内部，形成未固化的光纤束；
将未固化的光纤束牵引至固化装置，形成固化后的光纤束；
将固化后的光纤束牵引至第一挤塑模具，在固化后的光纤束外周面挤塑二次被覆层；固化后的光纤束与二次被覆层共同形成光单元；
将多根光单元绕中心加强件绞合，并在多根光单元的绞合缝隙内填充密封胶；中心加强件、多根光单元以及密封胶共同形成缆芯；
在缆芯外周面挤塑外护套，外护套与缆芯共同形成微缆。具体的，采用第二挤塑模具在缆芯外周面挤塑外护套，第二挤塑模具为挤压式模具。
在上述过程中，可以设置并线模具、涂覆模具、固化装置以及挤塑模具位于同一水平线上，这样设置，有利于保证光纤放线张力一致，减小光纤的衰减系数。
在一些实施例中，在将固化后的光纤束牵引至第一挤塑模具，在固化后的光纤束外周面挤塑二次被覆层的步骤包括：
对挤塑模具的挤塑通道进行抽真空处理，以控制二次被覆层与固化后的光纤束之间的松紧程度。其中，抽真空处理可以采用抽真空机来进行，且二次被覆层与固化后的光纤束之间的松紧程度可以通过抽真空机显示的真空度来控制。这样设置，可通过调节真空压力保证光纤二次被覆层与光纤束之间具有良好的气密性和阻水性，使光单元表面光滑、外观圆整。
进一步的，在将多根光单元绕中心加强件绞合，并在多根光单元的绞合缝隙内填充密封胶的步骤中，可采用上述实施例中的填充装置，且多根光单元绞合时的放线张力控制在3N～5N之间。具体的，将中心加强件与多根光单元穿设在填充通道内，且使中心加强件与多根光单元沿填充通道的长度方向运动，同时使多根光单元绕中心加强件绞合，在绞合的过程中，从注胶阀流出的密封胶经过注胶通道、填充通道后填充于多根光单元的绞合缝隙中。中心加强件与多根光单元在经过绞合与填充之后可以初步形成缆芯。
初步形成的缆芯在经过填充孔道的填充出口处的过线模后可以去除缆芯表面多余的密封胶，提高缆芯的圆整度。
由于采用了上述填充装置，因此本实施例提供的微缆制造方法可以通过气源调节注胶阀内的气压大小，从而确保密封胶能完全填充在多根光单元的绞合缝隙中，提高了微缆的性能。
在一些可能的实施例中，在缆芯经过过线模之后，还包括将缆芯送入加热装置的步骤，以加速缆芯的固化。
示例性地，上述各方法实施例中微缆的结构与材料均可以参见上述产品实施例，此处不再赘述。
本说明书中各实施例或实施方式采用递进的方式描述，每个实施例重点说明的都是与其他实施例的不同之处，各个实施例之间相同相似部分相互参见即可。
本领域技术人员应理解的是，在本申请的揭露中，术语“纵向”、“横向”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”等指示的方位或位置关系是基于附图所示的方位或位置关系，其仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的系统或元件必须具有特定的方位、以特定的方位构造和操作，因此上述术语不能理解为对本申请的限制。
在本说明书的描述中，参考术“一个实施方式”、“一些实施方式”、“示意性实施方式”、“示例”、“具体示例”、或“一些示例”等的描述意指结合实施方式或示例描述的具体特征、结构、材料或者特点包含于本申请的至少一个实施方式或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施方式或示例。而且，描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施方式或示例中以合适的方式结合。
最后应说明的是：以上各实施例仅用以说明本申请的技术方案，而非对其限制；尽管 参照前述各实施例对本申请进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本申请各实施例技术方案的范围。
以上所述，仅为本申请的具体实施方式，但本申请的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本申请揭露的技术范围内，可轻易想到的变化或替换，都应涵盖在本申请的保护范围之内。因此，本申请的保护范围应以所述权利要求的保护范围为准。

Claims (12)

  1. 一种微缆，其特征在于，包括缆芯和包覆所述缆芯外周面的外护套，所述缆芯包括中心加强件、多根光单元以及密封胶，多根所述光单元绕所述中心加强件绞合，所述密封胶填充于多根所述光单元的绞合缝隙内。
  2. 根据权利要求1所述的微缆，其特征在于，所述密封胶的材质包括活性树脂、增稠剂以及增粘剂，其中，所述增稠剂和所述增粘剂均匀的混合在所述活性树脂中。
  3. 根据权利要求2所述的微缆，其特征在于，所述密封胶固化后的硬度为35HA～45HA，所述密封胶固化后的密度为1.2g/cm 3～1.4g/cm 3。
  4. 根据权利要求1所述的微缆，其特征在于，所述光单元包括光纤束，所述光纤束包括多根光纤和固化树脂，多根所述光纤呈束状间隔分布在所述固化树脂内部。
  5. 根据权利要求4所述的微缆，其特征在于，所述固化树脂为热固化树脂；
    所述光单元还包括包覆所述光纤束外周面的二次被覆层，所述二次被覆层的材质包括聚对苯二甲酸丁二醇酯，且所述二次被覆层的厚度为0.1mm～0.3mm。
  6. 根据权利要求5所述的微缆，其特征在于，每根所述光纤束中的光纤数量为12根或24根；
    当每根所述光纤束中的光纤数量为12根时，所述光纤束的直径为0.9mm～1.2mm，所述光单元的直径为1.3mm～1.7mm；
    当每根所述光纤束中的光纤数量为24根时，所述光纤束的直径为1.4mm～1.7mm，所述光单元的直径为1.6mm～2.3mm。
  7. 根据权利要求4所述的微缆，其特征在于，所述固化树脂为光固化树脂，所述光固化树脂包括基础树脂、光敏剂以及活性剂，其中，所述光敏剂与所述活性剂均匀混合在所述基础树脂中。
  8. 根据权利要求7所述的微缆，其特征在于，每根所述光纤束中的光纤数量为12根或24根；
    当每根所述光纤束中的光纤数量为12根时，所述光纤束的直径为1.0mm～1.5mm；
    当每根所述光纤束中的光纤数量为24根时，所述光纤束的直径为1.5mm～2.0mm。
  9. 根据权利要求1-8任一项所述的微缆，其特征在于，所述外护套的材质为聚氨酯弹性体、聚氯乙烯、热塑性弹性体、热塑性聚酯弹性体中的至少一种；
    所述外护套的厚度为0.4mm～0.8mm。
  10. 一种填充装置，其特征在于，所述填充装置包括注胶并线模、注胶阀、密封胶泵以及气源，所述注胶并线模内设置有填充通道和注胶通道，
    所述填充通道包括填充入口与填充出口，中心加强件与多根光单元从所述填充入口穿入所述填充通道，从所述填充出口穿出所述填充通道；所述注胶通道的一端与所述注胶阀连通，另一端与所述填充通道连通；所述密封胶泵和所述气源均与所述注胶阀连通；
    所述密封胶泵用于向所述注胶阀内泵注密封胶；所述气源用于调节所述注胶阀内的气压大小，以控制所述注胶阀的出胶速度；所述填充通道用于向多个所述光单元的绞合缝隙内填充所述密封胶。
  11. 一种微缆的制造方法，其特征在于，包括：
    提供中心加强件与多根光纤；
    对多根所述光纤均匀放线，使多根所述光纤经过并线模具，以使多根所述光纤呈束状间隔排布；
    将呈束状间隔排布的多根所述光纤牵引至涂覆模具中，使多根所述光纤呈束状间 隔分布在固化树脂内部，形成未固化的光纤束；
    使未固化的光纤束经过固化装置，形成固化后的光纤束；
    将固化后的光纤束牵引至第一挤塑模具中，在固化后的光纤束外周面挤塑二次被覆层；固化后的光纤束与二次被覆层共同形成光单元；
    将多个所述光单元绕所述中心加强件绞合，并在多个所述光单元的绞合缝隙内填充密封胶；所述中心加强件、多个所述光单元以及所述密封胶共同形成缆芯；
    在所述缆芯外周面挤塑外护套，所述外护套与所述缆芯共同形成微缆。
  12. 根据权利要求11所述的微缆的制造方法，其特征在于，将固化后的光纤束牵引至挤塑模具中，在固化后的光纤束外周面形成二次被覆层的步骤包括：
    对所述挤塑模具的挤塑通道进行抽真空处理，以控制所述二次被覆层与所述固化后的光纤束之间的松紧程度。
PCT/CN2021/116614 2021-06-17 2021-09-06 微缆及其制造方法、填充装置 WO2022262124A1 (zh)

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