Lightweight water floating photoelectric composite cable and preparation method thereof

Abstract

The invention relates to a light-weight water floating photoelectric composite cable. An inner sheath layer, a sectional buoyancy layer, a tensile reinforcing layer and an outer sheath layer are sequentially wrapped outside a photoelectric composite cable core; the photoelectric composite cable core is formed by twisting a conductive core wire and an optical fiber unit, water-blocking yarns are filled between the conductive core wire and the optical fiber unit, and a water-blocking tape is wrapped outside the photoelectric composite cable core; the sectional type buoyancy layer is arranged in a sectional mode in the length direction of the cable, a continuous sealing structure is formed between every two adjacent sections through hot melting, and an electronic tag is embedded in the sectional type buoyancy layer; and each section of the sectional buoyancy layer is of a structure with a large middle part and two small ends. Due to the structure of the sectional buoyancy layer, the overall size is lighter, impact force can be dispersed and dynamic stability can be kept when the water flow impact occurs, and the tensile strength is improved by 60% in cooperation with the tensile reinforcing layer. The double-layer sectional buoyancy layer structure can adjust and control the buoyancy during manufacturing according to the use occasion of the cable so as to adapt to the requirements of different water depths and loads.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, specifically to a lightweight water-floating optoelectronic composite cable and a preparation method thereof, and more particularly to a lightweight water-floating optoelectronic composite cable for use in a dynamic water environment and having both power transmission and optical signal transmission functions and a preparation method thereof. Background Art

[0002] In the existing technology, traditional water cables mostly use lead sheaths or armored structures to enhance mechanical strength, but they have problems such as heavy weight, insufficient buoyancy, and high laying costs.

[0003] Although existing floating cables on the market achieve floating on the water surface by adding buoyancy materials, they have the following defects:

[0004] 1. Structural redundancy: The traditional cable's separated optical and electrical unit design results in increased volume and weight;

[0005] 2. Poor weather resistance: The outer sheath material has insufficient resistance to UV and salt spray corrosion, and is prone to aging and cracking after long-term exposure;

[0006] 3. Weak dynamic adaptability: It is easy to deform under the impact of water flow, resulting in internal optical fiber signal attenuation or conductive core breakage;

[0007] 4. Uncontrollable buoyancy: A single buoyancy layer is difficult to adapt to different water depths and load requirements.

[0008] Therefore, there is an urgent need for a lightweight, highly reliable, and customizable buoyancy floating optoelectronic composite cable. Summary of the Invention

[0009] The purpose of the present invention is to provide an improved lightweight water-floating optoelectronic composite cable and a preparation method thereof. By improving the structure and preparation method, the optoelectronic composite cable can achieve high buoyancy and lightweight while maintaining dynamic stability and reducing manufacturing costs.

[0010] In order to achieve the above-mentioned purpose, the technical solution of the present invention is: a lightweight water-floating optoelectronic composite cable, characterized in that: the optoelectronic composite cable includes an optoelectronic composite cable core, and the optoelectronic composite cable core is wrapped with an inner sheath layer, a segmented buoyancy layer, a tensile reinforcement layer and an outer sheath layer in sequence; the optoelectronic composite cable core is formed by twisting a conductive core wire and an optical fiber unit, and the space between the conductive fiber core and the optical fiber unit is filled with water-blocking yarn, and the outside of the optoelectronic composite cable core is wrapped with a water-blocking tape; the segmented buoyancy layer is segmented along the length direction of the cable, and the length of each segment is 1-5m. A continuous sealing structure is formed between adjacent segments by hot melting, and an electronic tag is embedded in the segmented buoyancy layer; each segment of the segmented buoyancy layer has a structure with a larger middle and smaller ends, and the diameter in the middle is 1.2-2.2 times the diameter of the two ends.

[0011] Preferably, there are 3-5 conductive fiber cores, made of copper-clad aluminum wire with a tinned outer layer; the optical fiber unit is a loose tube structure, containing 1-12 cores of single-mode optical fiber, and the loose tube is filled with water-blocking fiber paste.

[0012] Furthermore, the inner sheath layer is formed by blending low-density polyethylene LDPE and ethylene-vinyl acetate copolymer EVA, and has a thickness of 0.8 to 1.5 mm.

[0013] Furthermore, each segmented buoyancy layer is provided with an inner and outer buoyancy layer. The inner buoyancy layer is a structure that is large at both ends and narrow in the middle, while the outer buoyancy layer is a structure that is large in the middle and narrow at both ends. The relationship between the two needs to satisfy the following formula:

[0014] (d 内中 +d 内端 ) / (d 外中 +d 外端 ) ratio is 0.4-0.82;

[0015] The inner layer is made of nitrile rubber foam material with a density of 75-120kg / m 3 The outer layer is made of closed-cell foamed polyurethane PU or cross-linked polyethylene XLPE with a density of 0.05-0.25g / cm 3 .

[0016] Furthermore, the tensile reinforcement layer adopts a double-layer woven structure, the inner layer is an aramid fiber woven mesh with a weaving angle of 30° to 45°; the outer layer is a spirally wound ultra-high molecular weight polyethylene UHMWPE unidirectional tape with a tensile strength of ≥2000MPa and a strain rate of ≤3%.

[0017] Furthermore, the outer sheath layer is made of a composite modified material of polyurethane PU and nano-titanium dioxide, with a thickness of 1.2 to 2.0 mm, and a concave-convex texture is provided on the surface of the outer sheath layer.

[0018] A method for preparing a lightweight water-floating optoelectronic composite cable is characterized in that the method comprises the following steps: a. preparing a cable core: twisting a conductive core wire with an optical fiber unit, filling the cable with water-blocking yarn, and then extruding an inner sheath layer; b. preparing a segmented buoyancy layer: first preparing an inner buoyancy layer, extruding a foaming material in segments on the surface of the inner buoyancy layer using a continuous foaming device to form an outer buoyancy layer, and simultaneously heat-welding the foaming material to form a sealed buoyancy layer; c. preparing a tensile reinforcement layer: using a high-speed braiding machine to prepare an aramid fiber mesh, and spirally wrapping an ultra-high molecular weight polyethylene (UHMWPE) tape around the outer surface of the inner aramid fiber mesh to form a double-layer braided layer; d. extruding an outer sheath: the outer sheath adopts a double-layer co-extrusion process, with the inner layer being a wear-resistant polyurethane and the outer layer being an anti-UV modified layer.

[0019] Preferably, in step a, there are 3-5 conductive fiber cores, copper-clad aluminum wire is used, and the outer layer is provided with a tinned layer; the optical fiber unit is a loose tube structure, containing 1-12 cores of single-mode optical fiber, and the loose tube is filled with water-blocking fiber paste.

[0020] Furthermore, in step d, a fluorescent coating is coated on the surface of the outer sheath so that the nighttime visibility distance is greater than or equal to 500m, and a concave-convex pattern is provided on the surface of the outer sheath layer.

[0021] Furthermore, in step b, outward curling edges are provided at both ends of the inner buoyancy layer, and inward curling edges are provided at both ends of the outer buoyancy layer. The inner and outer curling edges fit together to facilitate heat welding to form a closed buoyancy layer.

[0022] Compared with the prior art, the technical solution of the present invention not only improves the overall technical solution, but also includes many improvements in details. Specifically, it has the following beneficial effects:

[0023] 1. The improved solution of the present invention comprises a segmented buoyancy layer arranged along the length of the cable, with each segment being 1-5 meters in length. Adjacent segments are heat-fused to form a continuous seal. An electronic tag is embedded in the segmented buoyancy layer. Each segment of the segmented buoyancy layer is larger in the middle and smaller at the ends, with the diameter in the middle being 1.2-2.2 times the diameter at the ends. This results in a significant segmented buoyancy effect. The buoyancy value of the double-layer structure is adjustable, making it suitable for different water depths and load requirements.

[0024] 2. In the technical solution of the present invention, the tensile reinforcement layer adopts a double-layer braided structure. The inner layer is an aramid fiber braided mesh with a braiding angle of 30° to 45°; the outer layer is a spirally wound ultra-high molecular weight polyethylene (UHMWPE) unidirectional tape with a tensile strength of ≥2000MPa and a strain rate of ≤3%. This makes the cable less likely to deform under water impact, ensures that the optical fiber signal will not attenuate, and the conductive core is not easily broken, thereby extending the service life.

[0025] 3. In the structure of the present invention, the optoelectronic composite cable core is formed by twisting a conductive core wire and an optical fiber unit. The space between the conductive fiber core and the optical fiber unit is filled with water-blocking yarn. The outside of the optoelectronic composite cable core is wrapped with a water-blocking tape, which reduces the overall weight and is a lightweight floating cable.

[0026] 4. The preparation method of the present invention is simple and easy to implement, has a high yield, reduces production costs, and is easy to promote and utilize. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 Schematic diagram of the cable cross-section structure of the present invention.

[0028] Figure 2 Schematic diagram of the weaving angles of the segmented buoyancy layer and the tensile reinforcement layer of the present invention.

[0029] Figure 3 Schematic diagram of the SZ alternating arrangement of the stranded cable core of the present invention.

[0030] Reference numerals:

[0031] 1. Optical fiber unit, 2. Water-blocking grease, 3. Loose tube, 4. Electronic tag, 5. Conductive core wire, 6. Insulation layer, 7. Water-blocking yarn, 8. Water-blocking tape, 9. Inner sheath layer, 10. Segmented buoyancy layer, 11. Tensile reinforcement layer, 12. Outer sheath layer, 13. Optoelectronic composite cable core. DETAILED DESCRIPTION

[0032] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0033] The present invention provides a lightweight water-floating optoelectronic composite cable. Figure 1 The difference between the optical fiber cable and the prior art is that: the optical fiber cable includes an optical fiber composite cable core 13, which is sequentially wrapped with an inner sheath layer 9, a segmented buoyancy layer 10, a tensile reinforcement layer 11 and an outer sheath layer 12; the optical fiber composite cable core is twisted by a conductive core wire 5 and an optical fiber unit 1, and a water-blocking yarn 7 is filled between the conductive fiber core and the optical fiber unit. The outer surface of the optical fiber composite cable core is wrapped with a water-blocking tape 8, which makes the cable core smaller and lighter after cabling, and the density is reduced by 40-50% compared with traditional cables; the segmented buoyancy layer is segmented along the length of the cable, with each segment being 1-5m long. A continuous sealing structure is formed between adjacent segments by hot melting, and an electronic tag is embedded in the segmented buoyancy layer; each segment of the segmented buoyancy layer has a structure with a larger middle and smaller ends, and the diameter of the middle is 1.2-2.2 times the diameter of the two ends.

[0034] During use, the segmented buoyancy layer, with each section larger in the middle and smaller at the ends, makes the cable lighter and more agile on the water surface. When impacted by currents, it disperses the impact force, maintaining dynamic stability. Combined with the tensile reinforcement layer, the tensile strength is increased by 60%. Furthermore, the double-layer segmented buoyancy layer structure allows for adjustment and control of buoyancy during fabrication, tailored to the cable's intended use, to accommodate varying water depths and loads.

[0035] Example 1

[0036] In this embodiment, a lightweight floating photovoltaic composite cable is described. Figure 1The optoelectronic composite cable includes an optoelectronic composite cable core, which is wrapped with an inner sheath layer 9, a segmented buoyancy layer 10, a tensile reinforcement layer 11 and an outer sheath layer 12 in sequence; the optoelectronic composite cable core is formed by twisting a conductive core wire 5 and an optical fiber unit 1, and a water-blocking yarn 7 is filled between the conductive fiber core and the optical fiber unit. The outside of the optoelectronic composite cable core is wrapped with a water-blocking tape 8, so that the cable core after cabling is smaller and lighter, and the density is reduced by 40-50% compared with traditional cables; the segmented buoyancy layer is segmented along the length of the cable, each segment is 1-5m long, and a continuous sealing structure is formed between adjacent segments by hot melting, and an electronic tag 4 is embedded in the segmented buoyancy layer; each segment of the segmented buoyancy layer has a structure with a larger middle and smaller ends, and the diameter in the middle is 1.2-2.2 times the diameter of the two ends.

[0037] Specifically, preferably, the number of conductive fiber cores is 3-5, using copper-clad aluminum wire with a cross-sectional area of ​​1.5-10mm 2 The outer layer is provided with a tinned layer to improve corrosion resistance; the optical fiber unit is a loose tube structure, containing 1-12 core single-mode optical fibers, the loose tube 3 is filled with water-blocking fiber paste 2, and the cable core gap is filled with water-blocking yarn, with a water-blocking rate ≥0.1MPa·h.

[0038] Furthermore, the inner sheath layer is made of a blend of 30-45% by mass of low-density polyethylene LDPE and 42-58% by mass of ethylene-vinyl acetate copolymer EVA, with a thickness of 0.8-1.5 mm and a density of ≤0.92 g / cm 3 , tensile strength ≥10MPa, elongation at break ≥400%.

[0039] Preferably, spiral carvings are printed on the inner side of the inner sheath layer. Due to the provision of the above carvings, the tensile strength and elongation at break are further improved, with the tensile strength being ≥10.5 MPa and the elongation at break being ≥430%.

[0040] Furthermore, the segmented buoyancy layer is composed of closed-cell foamed polyurethane (PU) or cross-linked polyethylene (XLPE) with a density of 0.05-0.25 g / cm 3 , thickness 3-15mm; the buoyancy layer is designed in sections along the length of the cable, with each section being 1-5m long. The sections are welded together to form a continuous sealing structure, and the section buoyancy value is adjustable (50-200N / m).

[0041] Specifically, each segment of the segmented buoyancy layer has an inner and outer buoyancy layer. The inner buoyancy layer has a structure that is large at both ends and narrow in the middle, while the outer buoyancy layer has a structure that is large in the middle and narrow at both ends. The relationship between the two needs to satisfy the following formula:

[0042] (d 内中 +d 内端 ) / (d 外中 +d 外端) is 0.4-0.82, with a preferred value of 0.65;

[0043] The inner layer is made of nitrile rubber foam material with a density of 75-120kg / m 3 The outer layer is made of closed-cell foamed polyurethane PU or cross-linked polyethylene XLPE with a density of 0.05-0.25g / cm 3 .

[0044] Furthermore, the tensile reinforcement layer adopts a double-layer woven structure, the inner layer is an aramid fiber woven mesh with a weaving angle of 30° to 45°; the outer layer is a spirally wound ultra-high molecular weight polyethylene UHMWPE unidirectional tape with a tensile strength of ≥2000MPa and a strain rate of ≤3%.

[0045] Furthermore, the outer sheath is made of a modified composite material consisting of 30-50% polyurethane (PU) and 45-65% nano-titanium dioxide (TiO2) by weight, with a thickness of 1.2-2.0 mm. The outer sheath features a embossed surface to increase resistance and extend service life. The outer sheath also contains 2-3% by weight of a UV absorber (benzotriazole) and 1.5-3% of an antioxidant (phosphite), achieving a salt spray resistance test of ≥2000 hours without cracking.

[0046] This lightweight, floating photovoltaic composite cable utilizes an integrated photovoltaic composite cable core design, a segmented buoyancy layer, and a double-layer tensile reinforcement structure to achieve high buoyancy, dynamic impact resistance, and a long lifespan. It is suitable for applications such as marine energy development and emergency communications, offering significant economic and reliability advantages.

[0047] Example 2

[0048] In this embodiment, a method for preparing a lightweight water-floating optoelectronic composite cable is described, and the preparation method includes the following steps: a. cable core preparation: twisting the conductive core wire with the optical fiber unit, filling it with water-blocking yarn, and then extruding an inner sheath layer; b. making a segmented buoyancy layer: first making an inner buoyancy layer, and then extruding a foaming material in segments on the surface of the inner buoyancy layer through a continuous foaming device to form an outer buoyancy layer, and simultaneously heat-welding it to form a closed buoyancy layer; c. making a tensile reinforcement layer: using a high-speed braiding machine to complete an aramid fiber mesh, and spirally wrapping an ultra-high molecular weight polyethylene (UHMWPE) tape around the outside of the inner aramid fiber mesh to form a double-layer braided layer; d. extruding an outer sheath: the outer sheath adopts a double-layer co-extrusion process, the inner layer is a wear-resistant polyurethane, and the outer layer is an anti-UV modified layer.

[0049] Preferably, in step a, there are 4 conductive fiber cores, using 6mm 2The copper-clad aluminum wire is tinned. The loose-tube fiber unit contains two six-core single-mode optical fibers, filled with water-blocking jelly. The stranding ratio of the conductive core and the optical fiber unit is 8 to 12 times the cable core diameter, with the strands alternating in the S and Z directions to reduce electromagnetic interference.

[0050] Furthermore, in step d, the outer sheath is coated with a fluorescent coating, ensuring nighttime visibility of at least 500 meters. The outer sheath is also patterned with undulating patterns. These patterns consist of four to six water-ripple grooves arranged along the cable's axial direction, and raised dots arranged along the cable's radial direction. Each segmented buoyancy layer is provided with at least two circles of raised dots, each containing 10 to 25 dots.

[0051] In step b, the segmented buoyancy layer is composed of closed-cell foamed polyurethane (PU) or cross-linked polyethylene (XLPE) with a density of 0.05-0.25 g / cm 3 , thickness 3 to 15 mm; the buoyancy layer is designed in sections along the length of the cable, with each section being 2 m long, and a continuous sealing structure is formed between sections by heat welding, with a section buoyancy value of 120 N / m.

[0052] The two ends of the inner buoyancy layer are provided with outward curling edges, and the two ends of the outer buoyancy layer are provided with inward curling edges. The inner and outer curling edges fit together to facilitate heat welding to form a closed buoyancy layer. After the heat welding is completed here, it is necessary to keep it warm at 120 degrees for 30 minutes, then cool it to room temperature, and then keep it warm at 150 degrees for 20 minutes again. In this way, the inner and outer buoyancy layers with relatively perfect shape and density can be obtained. The formed heat-welded sealed buoyancy layer is not only a sealed structure as a whole, but each individual segmented buoyancy layer is also sealed. Once one of them is damaged, it will not affect the buoyancy of other layers, and the cable can still be kept floating, extending its service life.

[0053] Furthermore, a circle of perlite particles is set in the outward curl of the inner buoyancy layer. When it encounters heat, it will expand rapidly to form a honeycomb structure, which not only increases the size of the curl and improves the buoyancy, but also makes the sealing and waterproofing effect better.

[0054] The advantages of the present invention are as follows:

[0055] Lightweight: The cable core integrates the photoelectric transmission function, and the density is 40% to 50% lower than that of traditional cables;

[0056] Dynamic stability: The segmented buoyancy layer can disperse the impact of water flow, and the double-layer reinforced structure increases the tensile strength by 60%;

[0057] Environmental adaptability: The weather resistance of the outer sheath meets the IEC 60811 standard, and the service life is extended to more than 15 years;

[0058] Intelligent management: RFID tags enable full life cycle tracking and reduce maintenance costs.

[0059] The above is a further detailed description of the present invention in conjunction with specific preferred embodiments, and it cannot be considered that the specific implementation of the present invention is limited to the above description. For those skilled in the art of the present invention, without departing from the concept of the present invention, several simple deductions or substitutions can be made, which should be considered to fall within the scope of protection of the present invention.

Claims

1. A lightweight floating photovoltaic composite cable, characterized by: The optoelectronic composite cable includes an optoelectronic composite cable core, which is sequentially wrapped with an inner sheath layer, a segmented buoyancy layer, a tensile reinforcement layer and an outer sheath layer. The optoelectronic composite cable core is twisted by a conductive core wire and an optical fiber unit. The space between the conductive fiber core and the optical fiber unit is filled with water-blocking yarn, and the outside of the optoelectronic composite cable core is wrapped with a water-blocking tape. The segmented buoyancy layer is segmented along the length of the cable, with each segment being 1-5m long. Adjacent segments are connected by hot melting to form a continuous sealing structure. An electronic tag is embedded in the segmented buoyancy layer. Each segment of the segmented buoyancy layer is large in the middle and small at both ends. The diameter in the middle is 1.2-2.2 times the diameter at both ends.

2. The lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: There are 3-5 conductive fiber cores, made of copper-clad aluminum wire with a tinned outer layer; the optical fiber unit is a loose tube structure, containing 1-12 cores of single-mode optical fiber, and the loose tube is filled with water-blocking fiber paste.

3. The lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: The inner sheath layer is made of a blend of low-density polyethylene LDPE and ethylene-vinyl acetate copolymer EVA, and has a thickness of 0.8 to 1.5 mm.

4. The lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: Each segmented buoyancy layer has an inner and outer buoyancy layer. The inner buoyancy layer has a structure that is large at both ends and narrow in the middle, while the outer buoyancy layer has a structure that is large in the middle and narrow at both ends. The relationship between the two needs to satisfy the following formula: (d 内中 +d 内端 ) / (d 外中 +d 外端 ) ratio is 0.4-0.82; The inner layer is made of nitrile rubber foam material with a density of 75-120kg / m 3 The outer layer is made of closed-cell foamed polyurethane PU or cross-linked polyethylene XLPE with a density of 0.05-0.25g / cm 3 .

5. The lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: The tensile reinforcement layer adopts a double-layer woven structure. The inner layer is an aramid fiber woven mesh with a weaving angle of 30° to 45°; the outer layer is a spirally wound ultra-high molecular weight polyethylene UHMWPE unidirectional tape with a tensile strength of ≥2000MPa and a strain rate of ≤3%.

6. The lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: The outer sheath layer is made of a composite modified material of polyurethane PU and nano titanium dioxide, with a thickness of 1.2 to 2.0 mm, and a concave and convex pattern is provided on the surface of the outer sheath layer.

7. The method for preparing a lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: The preparation method comprises the following steps: a. preparing a cable core: twisting a conductive core wire with an optical fiber unit, filling the cable with water-blocking yarn, and then extruding an inner sheath layer; b. making a segmented buoyancy layer: first making an inner buoyancy layer, then making an outer buoyancy layer on the surface of the inner buoyancy layer, and simultaneously heat-melting the layers to form a closed buoyancy layer; c. making a tensile reinforcement layer: using a high-speed braiding machine to prepare an aramid fiber mesh, and spirally wrapping an ultra-high molecular weight polyethylene (UHMWPE) tape around the outer surface of the inner aramid fiber mesh to form a double-layer braided layer; d. extruding an outer sheath: the outer sheath adopts a double-layer co-extrusion process, with the inner layer being a wear-resistant polyurethane and the outer layer being an anti-ultraviolet modified layer.

8. The method for preparing a lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: In step a, there are 3-5 conductive fiber cores, which are copper-clad aluminum wires with a tinned outer layer; the optical fiber unit is a loose tube structure, containing 1-12 cores of single-mode optical fibers, and the loose tube is filled with water-blocking fiber paste.

9. The method for preparing a lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: In step d, a fluorescent coating is applied to the surface of the outer sheath so that the nighttime visibility distance is greater than or equal to 500m, and a concave-convex pattern is provided on the surface of the outer sheath layer.

10. The method for preparing a lightweight water-floating optoelectronic composite cable according to claim 1, characterized in that: In step b, outward curling edges are provided at both ends of the inner buoyancy layer, and inward curling edges are provided at both ends of the outer buoyancy layer. The inner and outer curling edges fit together to facilitate heat welding to form a closed buoyancy layer.

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