A large-core optical cable based on a double-layer stranded cable core and its forming process

Abstract

The present invention discloses a large-core optical cable based on a double-layer stranded cable core and its forming process, including an optical cable body and a strengthening and protecting component. The optical cable body consists of a cable core, a water-blocking layer, a corrugated steel strip, and an outer sheath. The water-blocking layer is fitted and sleeved outside the cable core, the strengthening and protecting component is correspondingly sleeved outside the water-blocking layer, and the corrugated steel strip is correspondingly wrapped and sleeved outside the strengthening and protecting component. In the present invention, when the cable core is stranded, a special two-way stranding disc with internal gears is used. The inner layer places the inner-stranded sleeve, and the outer layer places the outer-stranded sleeve. The internal and external sleeves are simultaneously formed by one-time stranding through gear transmission. Different from the traditional double-layer stranded cable core that needs to first produce the inner-layer cable core and then strand the outer-layer cable core, this process is a one-time forming process for the internal and external layers of stranding, which improves the production efficiency. At the same time, the wire core adopts a 1 + 4 + 10 or 0 + 4 + 10 structure, different from the traditional 1 + 6 + 12 or 1 + 9 + 15 and other structures, making the optical cable have better bending performance and reducing the outer diameter of the optical cable, thus improving the construction efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of communication optical cables, and specifically relates to a large-core optical cable based on a double-layer stranded core structure and a forming process thereof. Background Art

[0002] Through the laying of duct optical cables, signal transmission is achieved. At present, due to the continuous advancement of 5G construction, there are more and more scenarios for the construction of optical cable ducts, resulting in a shortage of duct resources for duct optical cables, and traditional large-core optical cables have a long production cycle, are difficult to transport, and have an overly large outer diameter. On the other hand, due to the need for two stranding processes for traditional double-layer stranded cores, the production efficiency is low. Considering all these factors, this one-time forming process for a large-core double-layer stranded core structure and a large-core optical cable are designed.

[0003] The deficiencies of traditional devices are as follows: For the traditional double-layer stranded structure, in the cable-forming process, the central strengthening member and the inner sleeve are first stranded to obtain the inner cable core, and then the inner cable core is used as the central element and stranded with the outer sleeve for a second time to obtain the double-layer stranded cable core, realizing the formation of the optical cable core. Using this production method results in deficiencies such as a long production cycle, difficult transportation, and an overly large outer diameter for large-core optical cables. Summary of the Invention

[0004] The purpose of the present invention is to provide a large-core optical cable based on a double-layer stranded core structure and a forming process thereof to solve the problems mentioned in the above background.

[0005] To achieve the above purpose, the present invention provides the following technical solution: A large-core optical cable based on a double-layer stranded core structure, including an optical cable body and a strengthening and protecting component. The optical cable body consists of a cable core, a water-blocking layer, a corrugated steel strip, and an outer sheath. The water-blocking layer is fitted and sleeved outside the cable core, the strengthening and protecting component is correspondingly sleeved outside the water-blocking layer, the corrugated steel strip is correspondingly wrapped and sleeved outside the strengthening and protecting component, and the outer sheath is wrapped and sleeved outside the corrugated steel strip.

[0006] As a further preferred solution of this technical solution, the cable core is composed of multiple groups of wire cores, wire paste, multiple groups of water-blocking yarns, and two groups of strengthening members. The multiple groups of wire cores are hierarchically distributed in the cable core, and the multiple groups of wire cores are distributed in a 1 + 4 + 10 structure in the cable core. The water-blocking yarns are distributed at intervals between the wire cores. The strengthening members are symmetrically distributed in the cable core, and the wire paste is filled between the wire cores.

[0007] As a further preferred solution of this technical solution, the strengthening members are correspondingly distributed with the wire cores, and the strengthening members are made of a metal material.

[0008] As a further preferred embodiment of the present technical solution, the core is composed of multiple groups of optical fiber monomers, fiber paste and loose tubes, the multiple groups of optical fiber monomers are twisted in a circular shape, the loose tubes are sleeved on the outside of the multiple groups of optical fiber monomers, and the fiber paste is distributed between the optical fiber monomers and the loose tubes.

[0009] As a further preferred embodiment of the present technical solution, the reinforced protection component includes a fire retardant layer, a high temperature blocking layer and a flexible buffer layer. The high temperature blocking layer is wrapped around the outside of the water blocking layer, the flexible buffer layer is wrapped around the outside of the high temperature blocking layer, and the fire retardant layer is wrapped around the outside of the flexible buffer layer.

[0010] As a further preferred embodiment of the present technical solution, the fire-retardant layer is specifically made of natural rubber, the high-temperature blocking layer is specifically made of stainless steel, and the flexible buffer layer is specifically made of silicone.

[0011] As a further preferred embodiment of the present technical solution, the loose tube adopts a new secondary covering material, and the specific material of the loose tube is short glass fiber reinforced PBT.

[0012] A forming process for a large-core optical cable based on a double-layer twisted structure cable core.

[0013] The steps include:

[0014] S1, pre-selection of optical fiber raw materials: first, select materials with corresponding composition and diameter according to actual application requirements, and use an electrostatic eliminator to pre-clean the optical fiber raw materials;

[0015] S2, optical fiber coloring: the optical fiber raw materials selected in S1 are transported to the corresponding coloring mold for coloring, and then enter the ultraviolet curing furnace for rapid curing, and then pass through the take-up device for the wiring process;

[0016] S3, secondary coating: the PBT material is extruded from the extruder head and enters the hot water tank. When it melts, the viscous flow state is transformed into a highly elastic state. After that, it is stretched by the stretching equipment to the required outer diameter and wall thickness of the PBT bundle tube for use;

[0017] S4, one-time double-layer cabling: The cabling is performed by bundling the loose tubes by SZ twisting to achieve re-sheathing by placing the cable core in the center and extruding a layer of polyethylene material to form the optical cable;

[0018] The cabling process improves the twisting disc and adopts a transmission structure. During the rotation of the twisting disc, the internal steering beads move simultaneously to make the inner twisting disc and the outer twisting disc move synchronously in opposite directions and realize SZ twisting. The sleeves are placed in the twisting discs respectively to realize the inner and outer layers of the sleeves, and are placed in the twisting table for SZ twisting at the same time. By controlling the twisting speed, a double-layer structure cable core is formed at the same time, and a layer of polyethylene material is extruded to form the optical cable.

[0019] S5, Outer sheath extrusion: The co-extrusion of the outer sheath and the cable core is carried out by the head of the extruder, which shortens the overall processing cycle;

[0020] S6, Optical cable warehousing: After surface inspection and cleaning of the processed and formed optical cable, it is counted and warehoused for standby.

[0021] As a further optimization of this technical solution, the stranding machine used in S4 is a special equipment for producing cable cores, mainly used for stranding and twisting the cable cores of optical cables. In this solution, a differential stranding platform is used, and a two-way stranding disc with an internal gear is specially developed to realize the one-time forming process of the inner and outer layer cable cores in the forward and reverse directions.

[0022] As a further optimization of this technical solution, in the loose tube process of S3, the existing extrusion die is improved, the tension setting is optimized, and the loose tube adopts a structure of 1 tube with 12 - 48 cores.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] 1. Different from the traditional optical cable, the stranding production of the inner layer cable core and the outer layer cable core needs to be realized in two steps. The present invention uses a two-way stranding disc with an internal gear to realize the one-time forming process of the inner and outer layer cable cores. The synchronous stranding replaces the batch-by-batch stranding of the inner layer optical cable and the outer layer optical cable in the traditional optical cable sleeve stranding process, reduces the production time of the double-layer stranded cable core, and improves the production efficiency setting;

[0025] 2. By setting the number of cores per loose tube of the present invention to increase from the traditional 6 - 12 cores to 24 cores or even 48 cores and above, the outer diameter of the cable core can be reduced, the optical fiber density of the optical cable can be increased, and the structure of 1 + 4 + 10 or 0 + 4 + 10 is used, which is different from the traditional structures such as 1 + 6 + 12 or 1 + 9 + 15. This makes the optical cable have better bending performance and reduces the outer diameter of the optical cable, improves the construction efficiency. At the same time, the material used for the loose tube is a short glass fiber-reinforced PBT tube, which has better anti-side pressure and anti-compression flatness capabilities, and the breaking strength of the optical cable is improved;

[0026] 3. By setting the stranding and twisting of the cable core to adopt a special two-way stranding disc with an internal gear, the inner layer places the stranded loose tube of the inner layer, and the outer layer places the stranded loose tube of the outer layer. The one-time stranding and forming of the inner and outer layer loose tubes are realized by using gear transmission. Different from the traditional double-layer stranded cable core that needs to produce the inner layer cable core first and then strand the outer layer cable core, this process realizes the one-time forming process of the inner and outer layer stranding, and improves the production efficiency. Description of the Drawings

[0027] Figure 1 It is the overall front view of a large-core optical cable based on a double-layer stranded cable core and its forming process;

[0028] Figure 2Schematic diagram of the cable core of a large-core optical cable based on a double-layer stranded structure and its forming process;

[0029] Figure 3 Schematic diagram of the structure of the strengthening and protection component of a large-core optical cable based on a double-layer stranded structure and its forming process;

[0030] Figure 4 For a large-core optical cable based on a double-layer stranded structure cable core and its forming process Figure 2 Enlarged schematic diagram at position A;

[0031] Figure 5 Process flow chart of a large-core optical cable based on a double-layer stranded structure cable core and its forming process;

[0032] Figure 6 Schematic diagram of the structure of the stranding table of a large-core optical cable based on a double-layer stranded structure cable core and its forming process;

[0033] Figure 7 Schematic diagram of the overall structure of the stranding disc of a large-core optical cable based on a double-layer stranded structure cable core and its forming process;

[0034] Figure 8 Schematic diagram of the internal structure of the stranding disc of a large-core optical cable based on a double-layer stranded structure cable core and its forming process.

[0035] In the figure: 1. Optical cable body; 2. Cable core; 3. Water-blocking layer; 4. Corrugated steel strip; 5. Outer sheath; 6. Conductive core; 7. Conductive paste; 8. Water-blocking yarn; 9. Strengthening member; 10. Optical fiber unit; 11. Optical fiber paste; 12. Loose tube; 13. Fire and flame retardant layer; 14. High-temperature blocking layer; 15. Flexible buffer layer. Specific implementation mode

[0036] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention.

[0037] Embodiment 1

[0038] Please refer to Figures 1-4 , the present invention provides a technical solution: a large-core optical cable based on a double-layer stranded structure cable core, including an optical cable body 1 and a strengthening and protection component. The optical cable body 1 is composed of a cable core 2, a water-blocking layer 3, a corrugated steel strip 4, and an outer sheath 5. The water-blocking layer 3 is sleeved outside the cable core 2 in a fitting manner. The strengthening and protection component is correspondingly sleeved outside the water-blocking layer 3. The corrugated steel strip 4 is correspondingly wrapped outside the strengthening and protection component. The outer sheath 5 is wrapped outside the corrugated steel strip 4.

[0039] In this embodiment, specifically, the cable core 2 is composed of multiple groups of wire cores 6, wire paste 7, multiple groups of water-blocking yarns 8, and two groups of strengthening members 9. The multiple groups of wire cores 6 are hierarchically distributed in the cable core 2, and the multiple groups of wire cores 6 are distributed in a 1 + 4 + 10 structure in the cable core 2. The water-blocking yarns 8 are spaced and distributed between the wire cores 6. The strengthening members 9 are symmetrically distributed in the cable core 2, and the wire paste 7 is filled between the wire cores 6.

[0040] In this embodiment, specifically, the strengthening members 9 are correspondingly distributed with the wire cores 6, and the strengthening members 9 are made of a metal material.

[0041] In this embodiment, specifically, the wire core 6 is composed of multiple groups of optical fiber monomers 10, fiber paste 11, and a loose tube 12. The multiple groups of optical fiber monomers 10 are circularly stranded, the loose tube 12 is sleeved outside the multiple groups of optical fiber monomers 10, and the fiber paste 11 is distributed between the optical fiber monomers 10 and the loose tube 12.

[0042] In this embodiment, specifically, the enhanced protection component includes a fireproof and flame-retardant layer 13, a high-temperature blocking layer 14, and a flexible buffer layer 15. The high-temperature blocking layer 14 is wrapped and sleeved outside the water-blocking layer 3. The flexible buffer layer 15 is wrapped and sleeved outside the high-temperature blocking layer 14. The fireproof and flame-retardant layer 13 is wrapped and sleeved outside the flexible buffer layer 15.

[0043] In this embodiment, specifically, the fireproof and flame-retardant layer 13 is specifically made of natural rubber, the high-temperature blocking layer 14 is specifically made of stainless steel, and the flexible buffer layer 15 is specifically made of silica gel.

[0044] In this embodiment, specifically, the loose tube 12 uses a new secondary coating material, and the specific material of the loose tube 12 is short glass fiber-reinforced PBT.

[0045] Embodiment 2

[0046] Please refer to Figures 4-8 , a forming process of a large-core optical cable based on a double-layer stranded cable core,

[0047] including the following steps:

[0048] S1, preselection of optical fiber raw materials: First, select materials with corresponding components and diameters according to actual application requirements for standby, and at the same time, use an electrostatic cleaner to pre-clean the optical fiber raw materials;

[0049] S2, optical fiber coloring: Convey the optical fiber raw materials selected in S1 to the corresponding coloring molds for coloring treatment, then enter an ultraviolet light curing furnace for rapid curing, and then go through a wire winding device for wire arranging for standby;

[0050] S3, Secondary sheathing: After the PBT material is extruded from the head of the extruder, it enters the hot water tank. When it melts, the viscous flow state changes to the high elastic state, and then it is pulled and stretched by the stretching equipment to the required outer diameter and wall thickness of the PBT tube for standby;

[0051] S4, Primary double-layer cabling: Cabling is achieved by SZ stranding to bundle the loose tubes, and then the sheath is extruded. By placing the cable core in the center, a layer of polyethylene material is extruded to form the optical cable;

[0052] In the cabling process, through the improvement of the stranding disk, a transmission structure is adopted. During the rotation of the stranding disk, the internal turning beads move simultaneously, causing the inner stranding disk and the outer stranding disk to move in opposite directions synchronously and achieve SZ stranding. The tubes are respectively placed in the stranding disks to achieve the internal and external stratification of the tubes, and at the same time, they are placed in the stranding table for SZ stranding. By controlling the stranding speed, a cabling core with a double-layer structure is formed at the same time, and a layer of polyethylene material is extruded to form the optical cable;

[0053] S5, Outer sheath extrusion: The outer sheath and the cable core are co-extruded using the head of the extruder, shortening the overall processing cycle;

[0054] S6, Optical cable warehousing: The processed and formed optical cable is subjected to surface inspection and cleaning, and then counted and warehoused for standby.

[0055] In this embodiment, specifically, the cabling machine used in S4 is a special equipment for producing the cable core, mainly used for the cabling and stranding of the optical cable core. This solution utilizes a differential stranding table and specially develops a two-way stranding disk with internal gears to achieve the one-time forming process of the inner and outer layer cable cores in the forward and reverse directions.

[0056] In this embodiment, specifically, in the process of the loose tube 12 in S3, by improving the existing extrusion die and optimizing the tension setting, the tube adopts a structure of 1 tube with 12 - 48 cores.

[0057] Working principle: When in use, the cable core 2 of the optical cable body 1 is double-layer stranded. At the same time, the number of cores per tube of the sleeve increases from the traditional 6 - 12 cores to 24 cores or even 48 cores and above, which can reduce the outer diameter of the cable core 2 and increase the optical fiber density of the optical cable. Using the 1 + 4 + 10 or 0 + 4 + 10 structure, different from the traditional 1 + 6 + 12 or 1 + 9 + 15 structures, etc., enables the optical cable to have better bending performance, tensile performance, and reduces the outer diameter of the optical cable, improving the construction efficiency, enhancing the construction speed, saving pipeline resources. At the same time, the loose tube 12 is made of short glass fiber-reinforced PBT, which improves the bending, lateral pressure resistance, and compression resistance of the sleeve, solving the problem that the large-core simple structure optical cable is easily damaged. By distributing the water-blocking yarn 8 and the strengthening member 9 in the cable core 2, the flexibility of the optical cable is enhanced. By providing a strengthening and protection component and through the fireproof and flame-retardant layer 13, the fireproof treatment of the optical cable body 1 is realized, avoiding the rapid spread of internal and external fire sources, reducing the damaged area. At the same time, with the cooperation of the high-temperature blocking layer 14, it can block the high temperature generated by combustion and other conditions, avoiding damage to the inside of the cable core 2 caused by high temperature, etc., extending the service life of the optical cable body 1. At the same time, with the assistance of the flexible buffer layer 15, it can flexibly absorb the thermal expansion and contraction amount inside the cable core 2, ensuring the good use state of the optical cable body 1 and enhancing the safety during the use of the optical cable body 1.

[0058] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A large-core optical cable based on a double-layer stranded cable core, characterized in that, It includes an optical cable body (1) and a strengthening and protecting component. The optical cable body (1) consists of a cable core (2), a water-blocking layer (3), a corrugated steel strip (4), and an outer sheath (5). The water-blocking layer (3) is fitted and sleeved outside the cable core (2). The strengthening and protecting component is correspondingly sleeved outside the water-blocking layer (3). The corrugated steel strip (4) is correspondingly wrapped and sleeved outside the strengthening and protecting component. The outer sheath (5) is wrapped and sleeved outside the corrugated steel strip (4). Multiple groups of wire cores (6) are hierarchically distributed in the cable core (2), and the multiple groups of wire cores (6) are distributed in a 1 + 4 + 10 structure in the cable core (2). Two groups of strengthening members (9) are symmetrically distributed in the cable core (2).

2. The large-core optical cable based on a double-layer stranded core structure according to claim 1, characterized in that: The strengthening members (9) are correspondingly distributed with the wire cores (6), and the strengthening members (9) are made of a metal material.

3. The large-core optical cable based on a double-layer stranded core structure according to claim 2, characterized in that: The wire core (6) consists of multiple groups of optical fiber monomers (10), fiber paste (11), and a loose tube (12). The multiple groups of optical fiber monomers (10) are circularly stranded. The loose tube (12) is sleeved outside the multiple groups of optical fiber monomers (10). The fiber paste (11) is distributed between the optical fiber monomers (10) and the loose tube (12).

4. The large-core optical cable based on a double-layer stranded core structure according to claim 1, wherein: The strengthening and protecting component includes a fireproof and flame-retardant layer (13), a high-temperature blocking layer (14), and a flexible buffer layer (15). The high-temperature blocking layer (14) is wrapped and sleeved outside the water-blocking layer (3). The flexible buffer layer (15) is wrapped and sleeved outside the high-temperature blocking layer (14). The fireproof and flame-retardant layer (13) is wrapped and sleeved outside the flexible buffer layer (15).

5. The large-core optical cable based on a double-layer stranded core structure according to claim 4, characterized in that: The fireproof and flame-retardant layer (13) is specifically made of natural rubber. The high-temperature blocking layer (14) is specifically made of stainless steel. The flexible buffer layer (15) is specifically made of silica gel.

6. The large-core optical cable based on a double-layer stranded core structure according to claim 3, characterized in that: The loose tube (12) uses a new secondary coating material, and the specific material of the loose tube (12) is short glass fiber-reinforced PBT.

7. The forming process of a large-core optical cable based on a double-layer stranded core structure according to any one of claims 1-6, characterized in that: It includes the following steps: S1, Preliminary selection of optical fiber raw materials: First, select materials with corresponding components and diameters according to actual application requirements for standby. At the same time, use an electrostatic cleaner to pre-clean the optical fiber raw materials. S2, Optical fiber coloring: Convey the optical fiber raw materials selected in S1 to the corresponding coloring molds for coloring treatment, then immediately enter an ultraviolet light curing furnace for rapid curing, and then go through a wire winding device for wire arranging process for standby. S3, Secondary sheathing: Extrude the PBT material from the head of the extruder and then enter a hot water tank. When it melts, its viscous flow state changes to a highly elastic state, and then it is tractionally stretched by a stretching device to the required outer diameter and wall thickness of the PBT tube for standby. S4, Primary double-layer cabling: Cabling is achieved by SZ stranding to bundle the loose tubes. Then, by placing the cable core in the center and extruding a layer of polyethylene material to form the optical cable. The cabling process improves the stranding disk and adopts a transmission structure. During the rotation of the stranding disk, the internal steering beads move simultaneously, causing the inner stranding disk and the outer stranding disk to move in opposite directions synchronously and achieve SZ stranding. Place the tubes into the stranding disks respectively to achieve the internal and external stratification of the tubes, and at the same time place them in the stranding table for SZ stranding. By controlling the stranding speed, a cabling core with a double-layer structure is formed simultaneously, and a layer of polyethylene material is extruded to form the optical cable. S5, Outer Sheath Extrusion: The co-extrusion of the outer sheath and the cable core is carried out by the extruder head, which shortens the overall processing cycle; S6, Optical Cable Storage: The processed and formed optical cable is subjected to surface inspection and cleaning, and then counted and stored for standby.

8. The forming process of a large-core optical cable based on a double-layer stranded cable core according to claim 7, characterized in that: The stranding machine used in S4 is a special equipment for producing the cable core, mainly used for the stranding of the optical cable core. In this solution, a differential stranding table is utilized, and a two-way stranding disc with internal gears is specially developed to achieve the positive and negative one-time forming process of the inner and outer layer cable cores.

9. The forming process of a large-core optical cable based on a double-layer stranded core structure according to claim 7, characterized in that: In the loose tube process of S3, by improving the existing extrusion die and optimizing the tension setting, the loose tube adopts a structure of 1 tube with 12 - 48 cores.

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