Lightweight floating optical-electric composite cable and its preparation method

Abstract

This invention relates to a lightweight floating optical-electric composite cable. The optical-electric composite cable core is sequentially wrapped with an inner sheath layer, a segmented buoyancy layer, a tensile reinforcement layer, and an outer sheath layer. The optical-electric composite cable core is composed of conductive core wires and optical fiber units twisted together. Water-blocking yarn is filled between the conductive core and the optical fiber units, and water-blocking tape is wrapped around the outside of the optical-electric composite cable core. The segmented buoyancy layer is segmented along the cable length, with adjacent segments forming a continuous sealed structure through heat fusion. Electronic tags are embedded within the segmented buoyancy layer. Each segment of the segmented buoyancy layer has a structure that is larger in the middle and smaller at both ends. Due to the structure of the segmented buoyancy layer, the overall volume is lighter, and it can disperse the impact force when subjected to water flow, maintaining dynamic stability. Combined with the tensile reinforcement layer, the tensile strength is increased by 60%. The double-layered segmented buoyancy layer structure allows for adjustment and control of buoyancy during manufacturing, depending on the cable's application, to adapt to different water depths and load requirements.

Description

Technical Field

[0001] This invention relates to the technical field of cables, specifically to a lightweight floating optical-electric composite cable and its preparation method, and more particularly to a lightweight floating optical-electric composite cable with both power transmission and optical signal transmission functions for use in dynamic aquatic environments, and its preparation method. Background Technology

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

[0003] While existing floating cables on the market achieve buoyancy by adding buoyancy materials, they have the following drawbacks:

[0004] 1. Structural redundancy: The separate design of optoelectronic units in traditional cables leads to an increase in size and weight;

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

[0006] 3. Poor dynamic adaptability: It is prone to deformation under the impact of water flow, which can lead to attenuation of internal optical fiber signals or breakage of conductive core wires;

[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 floating optoelectronic composite cable. Summary of the Invention

[0009] The purpose of this invention is to provide an improved lightweight floating optoelectronic composite cable and its preparation method. Through improvements in structure and preparation method, the optoelectronic composite cable can achieve high buoyancy, lightweight, and dynamic stability, while also reducing manufacturing costs.

[0010] To achieve the above objectives, the technical solution of the present invention is: a lightweight floating optoelectronic composite cable, characterized in that: 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 formed by twisting conductive core wires and optical fiber units, with water-blocking yarn filling between the conductive core and the optical fiber units, and water-blocking tape wrapped around the outside of the optoelectronic composite cable core; the segmented buoyancy layer is segmented along the length of the cable, with each segment being 1-5m long, and adjacent segments are connected by heat fusion to form a continuous sealed structure, with electronic tags embedded in the segmented buoyancy layer; each segment of the segmented buoyancy layer has a structure that is larger in the middle and smaller at both ends, with the diameter of the middle being 1.2-2.2 times the diameter of the two ends.

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

[0012] Furthermore, the inner sheath layer is made of a blend of low-density polyethylene (LDPE) and ethylene-vinyl acetate copolymer (EVA), with a thickness of 0.8–1.5 mm.

[0013] Furthermore, each segment of the segmented buoyancy layer has inner and outer buoyancy layers. The inner buoyancy layer has a structure that is wider at both ends and narrower in the middle, while the outer buoyancy layer has a structure that is wider in the middle and narrower 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 The ratio is 0.4-0.82;

[0015] The inner layer is made of nitrile rubber foam with a density of 75-120 kg / m³. 3 The outer layer is made of closed-cell foamed polyurethane (PU) or cross-linked polyethylene (XLPE), with a density of 0.05-0.25 g / cm³. 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 made of ultra-high molecular weight polyethylene (UHMWPE) unidirectional spiral wound, with a tensile strength ≥2000MPa and a strain rate ≤3%.

[0017] Furthermore, the outer sheath is made of a composite modified material of polyurethane (PU) and nano-titanium dioxide, with a thickness of 1.2–2.0 mm, and the surface of the outer sheath is textured with raised and recessed patterns.

[0018] A method for preparing a lightweight floating optical-electric composite cable is characterized by the following steps: a) Core preparation: the conductive core wire is twisted with an optical fiber unit, filled with water-blocking yarn, and then an inner sheath layer is extruded; b) Segmented buoyancy layer preparation: the inner buoyancy layer is prepared first, and then foam material is extruded in segments on the surface of the inner buoyancy layer using a continuous foaming device to form an outer buoyancy layer, and simultaneously heat-fused to form a sealed buoyancy layer; c) Tensile reinforcement layer preparation: an aramid fiber mesh is completed using a high-speed braiding machine, and a double-layer braided layer is formed by spirally winding ultra-high molecular weight polyethylene (UHMWPE) tape around the outer side of the inner aramid fiber mesh; d) Outer sheath extrusion: the outer sheath adopts a double-layer co-extrusion process, with the inner layer being 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, which are made of copper-clad aluminum wire and have a tin-plated outer layer; the fiber unit is a loose tube structure, containing 1-12 single-mode optical fibers, and the loose tube is filled with water-blocking fiber paste.

[0020] Furthermore, in step d, the outer sheath surface is coated with a fluorescent coating, making the nighttime visibility distance greater than or equal to 500m, and the outer sheath layer surface is provided with a textured surface.

[0021] Furthermore, in step b, the inner buoyancy layer has outward rolled edges at both ends, and the outer buoyancy layer has inward rolled edges at both ends. The inner and outer rolled edges fit together to facilitate heat fusion 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 scheme of the present invention is that the segmented buoyancy layer is set in segments along the length of the cable, each segment being 1-5m long. Adjacent segments are connected by heat fusion to form a continuous sealed structure. Electronic tags are embedded in the segmented buoyancy layer. Each segment of the segmented buoyancy layer has a structure that is larger in the middle and smaller at both ends. The diameter of the middle is 1.2-2.2 times the diameter of the two ends, which makes the segmented buoyancy effect obvious. The buoyancy value of the double-layer structure is adjustable and 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 made of ultra-high molecular weight polyethylene (UHMWPE) unidirectional spiral winding with a tensile strength ≥2000MPa and a strain rate ≤3%. This makes the cable less prone to deformation under water flow impact, ensures that the optical fiber signal will not attenuate, and the conductive core wire is not prone to breakage, thus extending the service life.

[0025] 3. In the structure of the present invention, the optoelectronic composite cable core is made of conductive core wire and optical fiber unit twisted together. Water-blocking yarn is filled between the conductive core and the optical fiber unit. The optoelectronic composite cable core is wrapped with water-blocking tape, which reduces the overall weight and makes it 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. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the cable cross-section structure of the present invention.

[0028] Figure 2 This is a schematic diagram showing the weaving angles of the segmented buoyancy layer and tensile reinforcement layer of the present invention.

[0029] Figure 3 This is a schematic diagram of the alternating SZ arrangement of the stranded cable core of the present invention.

[0030] Figure label:

[0031] 1. Fiber optic unit, 2. Water-blocking fiber paste, 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 Implementation

[0032] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] This invention provides a lightweight floating optical-electric composite cable, see details below. Figure 1 The difference between this and existing technologies lies in the following: the optoelectronic composite cable includes an optoelectronic 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 optoelectronic composite cable core is made of conductive core wires 5 and optical fiber units 1 twisted together, with water-blocking yarn 7 filling the space between the conductive core and the optical fiber units, and water-blocking tape 8 wrapped around the outside of the optoelectronic composite cable core, resulting in a smaller cable core size, lighter weight, and a density reduction of 40-50% compared to traditional cables; the segmented buoyancy layer is set in segments along the length of the cable, with each segment being 1-5m long, and adjacent segments are connected by heat fusion to form a continuous sealed structure, with electronic tags embedded in the segmented buoyancy layer; each segment of the segmented buoyancy layer has a structure that is larger in the middle and smaller at both ends, with the diameter of the middle being 1.2-2.2 times the diameter of the two ends.

[0034] In use, the segmented buoyancy layer, with each segment being larger in the middle and smaller at both ends, makes the overall volume lighter and more agile on the water surface. When impacted by water flow, it can disperse the impact force and maintain dynamic stability. Combined with the tensile reinforcement layer, the tensile strength is increased by 60%. Furthermore, the double-layered segmented buoyancy layer structure allows for buoyancy adjustment and control during manufacturing, depending on the cable's application, to adapt to different water depths and load requirements.

[0035] Example 1

[0036] This embodiment describes a lightweight floating optical-electric composite cable, see details below. 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 made of conductive core wires 5 and optical fiber units 1 twisted together. Water-blocking yarn 7 is filled between the conductive core and the optical fiber unit. The optoelectronic composite cable core is wrapped with 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 set in segments along the length of the cable, each segment being 1-5m long. Adjacent segments are connected by heat fusion to form a continuous sealed structure. Electronic tags 4 are embedded in the segmented buoyancy layer. Each segment of the segmented buoyancy layer has a structure that is larger in the middle and smaller at both ends, with the diameter of the middle being 1.2-2.2 times the diameter of the two ends.

[0037] Specifically, preferably, the conductive fiber core consists of 3-5 strands, made of copper-clad aluminum wire, with a cross-sectional area of ​​1.5-10 mm². 2 The outer layer is tin-plated to improve corrosion resistance; the fiber unit is a loose tube structure containing 1-12 single-mode optical fibers, the loose tube 3 is filled with water-blocking fiber grease 2, and the gaps in the cable core are filled with water-blocking yarn, with a water blocking rate ≥0.1MPa·h.

[0038] Furthermore, the inner sheath layer is composed of 30-45% by weight of low-density polyethylene (LDPE) and 42-58% by weight of ethylene-vinyl acetate copolymer (EVA), with a thickness of 0.8-1.5 mm and a density ≤0.92 g / cm³. 3 Tensile strength ≥10MPa, elongation at break ≥400%.

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

[0040] Furthermore, the segmented buoyancy layer is composed of closed-cell polyurethane foam (PU) or cross-linked polyethylene (XLPE) with a density of 0.05-0.25 g / cm³. 3 The thickness is 3-15mm; the buoyancy layer is designed in sections along the length of the cable, each section is 1-5m long, and the sections are connected by heat fusion to form a continuous sealed structure. The buoyancy value of each section is adjustable (50~200N / m).

[0041] Specifically, each segment of the segmented buoyancy layer has inner and outer buoyancy layers. The inner buoyancy layer has a structure that is wider at both ends and narrower in the middle, while the outer buoyancy layer has a structure that is wider in the middle and narrower 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The ratio of ) is 0.4-0.82, with a preferred value of 0.65;

[0043] The inner layer is made of nitrile rubber foam with a density of 75-120 kg / m³. 3 The outer layer is made of closed-cell foamed polyurethane (PU) or cross-linked polyethylene (XLPE), with a density of 0.05-0.25 g / cm³. 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 made of ultra-high molecular weight polyethylene (UHMWPE) unidirectional spiral wound, with a tensile strength ≥2000MPa and a strain rate ≤3%.

[0045] Furthermore, the outer sheath is made of a composite modified material consisting of 30-50% polyurethane (PU) and 45-65% nano-titanium dioxide, with a thickness of 1.2-2.0 mm. The surface of the outer sheath features textured surfaces to increase resistance and extend service life. The outer sheath also contains 2-3% UV absorber (benzotriazole) and 1.5-3% antioxidant (phosphite), and exhibits no cracking after ≥2000 hours of salt spray testing.

[0046] This invention discloses a lightweight floating optoelectronic composite cable that achieves high buoyancy, resistance to dynamic impact, and long service life through an integrated design of the optoelectronic composite cable core, a segmented buoyancy layer, and a double-layer tensile reinforcement structure. It is suitable for applications such as marine energy development and emergency communications, offering significant economic and reliability advantages.

[0047] Example 2

[0048] This embodiment describes a method for preparing a lightweight floating optical-electric composite cable. The preparation method includes the following steps: a) Cable core preparation: the conductive core wire is twisted with an optical fiber unit, filled with water-blocking yarn, and then an inner sheath layer is extruded; b) Fabrication of segmented buoyancy layer: the inner buoyancy layer is first prepared, and then foam material is extruded in segments on the surface of the inner buoyancy layer using a continuous foaming device to form an outer buoyancy layer, and then simultaneously heat-fused to form a sealed buoyancy layer; c) Fabrication of tensile reinforcement layer: an aramid fiber mesh is completed using a high-speed braiding machine, and a double-layer braided layer is formed by spirally winding ultra-high molecular weight polyethylene (UHMWPE) tape around the outer side of the inner aramid fiber mesh; d) Extrusion of outer sheath: the outer sheath adopts a double-layer co-extrusion process, with the inner layer being wear-resistant polyurethane and the outer layer being an anti-ultraviolet modified layer.

[0049] Preferably, in step a, there are 4 conductive fiber cores, each 6mm in diameter. 2The cable is made of copper-clad aluminum wire with an outer tin-plated layer. The optical fiber unit has a loose tube structure, containing 2*6 core single-mode optical fibers, and the loose tube is filled with water-blocking fiber grease. The twisting pitch ratio between the conductive core wire and the optical fiber unit is 8 to 12 times the cable core diameter, and the twisting direction is alternately arranged in the S and Z directions to reduce electromagnetic interference.

[0050] Furthermore, in step d, the outer sheath surface is coated with a fluorescent coating, ensuring nighttime visibility of 500m or more. The outer sheath surface is also textured with raised patterns. These raised patterns consist of 4-6 wavy grooves along the cable axis and raised dots along the cable radial direction. Each segmented buoyancy layer has at least two rings of raised dots, with 10-25 dots in each ring.

[0051] In step b, the segmented buoyancy layer is composed of closed-cell polyurethane foam (PU) or cross-linked polyethylene (XLPE) with a density of 0.05–0.25 g / cm³. 3 The thickness is 3-15mm; the buoyancy layer is designed in sections along the length of the cable, each section is 2m long, and the sections are connected by heat fusion to form a continuous sealed structure, with a buoyancy value of 120N / m for each section.

[0052] The inner buoyancy layer has outward rolled edges at both ends, while the outer buoyancy layer has inward rolled edges at both ends. The inner and outer rolled edges fit together to facilitate heat fusion to form a sealed buoyancy layer. After the heat fusion is completed, it needs to be kept at 120 degrees Celsius for 30 minutes, then cooled to room temperature, and then kept at 150 degrees Celsius for 20 minutes. This process yields inner and outer buoyancy layers with a relatively perfect shape and density. The resulting heat-fused sealed buoyancy layer is not only a sealed structure as a whole, but each individual segmented buoyancy layer is also sealed. If one segment is damaged, it will not affect the buoyancy of the others, and the cable can still float, thus extending its service life.

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

[0054] The advantages of this invention are as follows:

[0055] Lightweight: The cable core integrates photoelectric transmission function, reducing density by 40% to 50% compared to traditional cables;

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

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

[0058] Intelligent management: RFID tags enable full lifecycle tracking, reducing maintenance costs.

[0059] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A lightweight floating optical-electric composite cable, characterized in that: The optoelectronic composite cable includes an optoelectronic composite cable core, which is sequentially wrapped with an inner sheath, a segmented buoyancy layer, a tensile reinforcement layer, and an outer sheath. The optoelectronic composite cable core is composed of conductive core wires and optical fiber units twisted together, with water-blocking yarn filling the space between the conductive core wires and the optical fiber units. The outside of the optoelectronic composite cable core is wrapped with water-blocking tape. The segmented buoyancy layer is segmented along the cable length, with each segment being 1-5m long. Adjacent segments are connected by heat fusion to form a continuous sealed structure. An electronic tag is embedded within the segmented buoyancy layer. Each segment of the segmented buoyancy layer has a structure that is larger in the middle and smaller at both ends, with the diameter of the middle being 1.2-2.2 times the diameter of the two ends. Each segment of the segmented buoyancy layer has inner and outer buoyancy layers. The inner buoyancy layer has a structure that is larger at both ends and narrower in the middle, while the outer buoyancy layer has a structure that is larger in the middle and narrower at both ends. The relationship between the two must satisfy the following formula: (d) 内中 +d 内端 ) / (d 外中 +d 外端 The ratio is 0.4-0.82; The inner layer is made of nitrile rubber foam with a density of 75-120 kg / m³. 3 The outer layer is made of closed-cell foamed polyurethane (PU) or cross-linked polyethylene (XLPE), with a density of 0.05-0.25 g / cm³. 3 The tensile reinforcement layer adopts a double-layer structure. The inner layer is an aramid fiber woven mesh with a weaving angle of 30° to 45°. The outer layer is made of ultra-high molecular weight polyethylene (UHMWPE) tape spirally wound, with a tensile strength ≥2000 MPa and a strain rate ≤3%.

2. The lightweight floating optical-electric composite cable according to claim 1, characterized in that: The conductive core consists of 3-5 wires, made of copper-clad aluminum wire, with an outer tin-plated layer; the optical fiber unit is a loose tube structure, containing 1-12 single-mode optical fibers, and the loose tube is filled with water-blocking fiber grease.

3. The lightweight floating optical-electric composite cable according to claim 1, characterized in that: The inner sheath layer is made of low-density polyethylene (LDPE) and ethylene-vinyl acetate copolymer (EVA), with a thickness of 0.8–1.5 mm.

4. The lightweight floating optical-electric composite cable according to claim 1, characterized in that: The outer sheath is double-layered, with an inner layer of wear-resistant polyurethane and an outer layer of UV-resistant modified layer. The outer sheath is 1.2–2.0 mm thick and has a textured surface.

5. The method for preparing a lightweight floating optoelectronic composite cable according to claim 1, characterized in that: The preparation method includes the following steps: a) Cable core preparation: the conductive core wire is twisted with the optical fiber unit, filled with water-blocking yarn, and then the inner sheath layer is extruded; b) Production of segmented buoyancy layer: the inner buoyancy layer is first produced, and the outer buoyancy layer is produced on the surface of the inner buoyancy layer, and the two layers are simultaneously heat-fused to form a closed buoyancy layer; c) Production of tensile reinforcement layer: the aramid fiber mesh is completed using a high-speed braiding machine, and ultra-high molecular weight polyethylene (UHMWPE) tape is spirally wound around the outer side of the inner aramid fiber mesh to form a double layer; d) Extrusion of outer sheath: the outer sheath adopts a double-layer co-extrusion process, with the inner layer being wear-resistant polyurethane and the outer layer being an anti-ultraviolet modified layer.

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

7. The method for preparing a lightweight floating optical-electric composite cable according to claim 5, characterized in that: In step d, the outer sheath surface is coated with a fluorescent coating to make it visible at night at a distance of 500m or more, and the outer sheath surface is provided with a textured surface.

8. The method for preparing a lightweight floating optoelectronic composite cable according to claim 5, characterized in that: In step b, the inner buoyancy layer has outward rolled edges at both ends, and the outer buoyancy layer has inward rolled edges at both ends. The inner and outer rolled edges fit together to facilitate heat fusion to form a closed buoyancy layer.

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