Optical cable protection structure and high-fiber-core-density comprehensive wiring structure and method

Abstract

The invention discloses an optical cable protection structure and a high-fiber-core-density comprehensive wiring structure and method.The optical cable protection structure adopts a graded buffer type stress relief structure and adopts a three-layer collaborative design of an elastic sleeve, a gradually-changed-thickness silica gel buffer sleeve and an aramid fiber woven mesh; the problem of stress concentration at the end joint of the high-core-number optical fiber ribbon is effectively solved, the stress level at an interface is remarkably reduced, and the reliability and long-term stability of connection are greatly improved. According to the high-fiber-core-density comprehensive wiring structure, the partial bonding type optical fiber ribbon, the full-dry type flexible sleeve, the optical cable protection structure and the high-density box body are organically integrated, the problem that in a traditional scheme, the performance of all assemblies is not matched is solved, the fiber core density is remarkably improved, meanwhile, the outer diameter and the weight of an optical cable are reduced, and unification of ultra-high density and small size is achieved.

Description

Technical Field

[0001] This invention belongs to the field of optical fiber technology, and particularly relates to an optical cable protection structure and a high fiber core density integrated cabling structure and method. Background Technology

[0002] In the integrated cabling of modern communication systems such as data centers and 5G bearer networks, the use of high-core-count, high-density optical fibers and cables has become an inevitable trend to meet the explosive growth in data transmission demands. However, as the core count of optical cables jumps from hundreds to thousands of cores, a series of severe technical challenges have emerged, restricting the large-scale and reliable application of this technology.

[0003] First, at the physical connection level, high-core-count fiber ribbons exhibit severe stress concentration at the termination points with standard connectors, easily leading to fiber breakage or performance degradation. For example, when the fiber ribbon core count reaches 1728, the mechanical strength and optical performance stability of its termination point face extreme challenges. Existing connection technologies often use a single heat-shrink tubing or a simple sheath for protection, with insufficient buffering capacity, failing to effectively cope with the complex stresses caused by tension during installation, vibration during use, and temperature changes. Tests show that the stress value at traditional termination structures often exceeds 80 MPa. This not only results in a persistently high fiber breakage rate during temperature cycling tests but also induces significant additional attenuation, becoming a potential failure point in high-reliability networks.

[0004] Secondly, at the system architecture level, the evolution of existing cabling structures towards ultra-high density has exposed systemic mismatches and inefficiencies. On the one hand, the traditional optical fibers used to achieve high density have poor flexibility, and their large bending radius combined with conventional conduits makes it difficult to reduce the outer diameter of the optical cable, limiting the utilization of conduit space. On the other hand, the number of optical cores in outdoor cables is insufficient, requiring the laying of a large number of optical cables, resulting in crowded cable trays, a large workload for construction, and the cumbersome and inefficient process of splicing traditional grease-filled optical cables on site. More importantly, there is a lack of coordinated design among components such as optical cables, connectors, and patch panels, often resulting in mismatches between the number of optical cores and patch panel capacity, difficulties in prefabrication and termination, and the inability to support "plug and play," making it impossible for the entire cabling system to simultaneously achieve high density, small size, lightweight, and rapid deployment. Summary of the Invention

[0005] To address the problems existing in the prior art, this invention proposes an optical cable protection structure and a high fiber density integrated cabling structure and method.

[0006] The technical solution of the present invention is as follows:

[0007] An optical cable protection structure is connected at the connection point between a high-core-count fiber optic ribbon and a standard connector interface. The optical cable protection structure includes an elastic sleeve, a silicone buffer sleeve fitted outside the elastic sleeve with a thickness that gradually decreases from the standard connector interface to the high-core-count fiber optic ribbon, and an aramid fiber braided mesh covering the silicone buffer sleeve, thereby forming a graded buffer stress relief structure.

[0008] Furthermore, the effective coverage sections of the elastic sleeve, silicone buffer sleeve, and aramid fiber braided mesh decrease sequentially from the standard connector interface end toward the fiber optic ribbon to achieve a gradient release of stress.

[0009] Furthermore, the elastic sleeve is made of beryllium bronze and has a built-in spring with a stiffness of 2-3 N / mm.

[0010] Furthermore, the silicone buffer sleeve has a Shore hardness of 40±5A and its thickness gradually changes from 2mm to 1mm.

[0011] Furthermore, the density of the aramid fiber woven mesh is 80 strands / cm², and it is bonded to the silicone cushioning sleeve by hot melt adhesive.

[0012] A high fiber density integrated cabling structure, including

[0013] The optical cable protection structure comprises a partially bonded optical fiber ribbon, a flexible sleeve fitted over the partially bonded optical fiber ribbon and employing a fully dry structure, a housing integrating a standard connector interface, and any of the above-described optical cable protection structures, wherein the optical cable protection structure is connected at the junction of the flexible sleeve and the standard connector interface.

[0014] Furthermore, the surface of the partially bonded optical fiber ribbon has bonding points formed by a double-sided dispensing process and distributed in a network, with a network distribution density of 0.5 to 1 point / mm².

[0015] A high fiber density structured cabling method, employing any of the high fiber density structured cabling structures described above, characterized in that the method includes:

[0016] Outdoor entry involves directly connecting pre-terminated outdoor optical cables to the main distribution frame in the equipment room.

[0017] Indoor interconnection connects pre-terminated indoor optical cables to pre-fabricated ports in the distribution box;

[0018] For device connection, use prefabricated patch cords to connect the patch panel to the device.

[0019] Furthermore, in the outdoor introduction, the number of outdoor optical cables used is 864 to 6912, and both ends are MPO connectors, which are directly connected to the main distribution frame through the MPO-MPO connection method.

[0020] Furthermore, in the indoor interconnection, the pre-fabricated indoor optical cable has an MPO or LC connector at its end;

[0021] And / or,

[0022] In the device connection, the prefabricated jumpers used are LC-LC jumpers, LC-MPO jumpers, or MPO-MPO connectors.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] This invention provides an optical cable protection structure, a high-fiber-density integrated cabling structure, and a method. The optical cable protection structure employs a graded buffer stress relief structure, utilizing a three-layer collaborative design of an elastic sleeve, a gradually thickening silicone buffer sleeve, and an aramid fiber braided mesh. This effectively solves the problem of stress concentration at the termination of high-fiber-count fibers, significantly reducing the stress level at the interface and greatly improving the reliability and long-term stability of the connection. Furthermore, this invention, through optimized component configuration, including a sleeve and spring combination of specific materials, a silicone buffer sleeve with specific hardness, an adjustable partition rib design, and the application of a high-density braided mesh, significantly improves the absorption and dispersion of stress, effectively addressing the poor compatibility issues of traditional buffer structures and ensuring stable protection under different fiber count specifications.

[0025] The high fiber density integrated cabling structure of this invention organically integrates partially bonded fiber ribbons, fully dry flexible sleeves, dedicated optical cable protection structures, and high-density enclosures, solving the problem of performance mismatch among components in traditional solutions, significantly improving fiber density, while reducing the outer diameter and weight of optical cables, achieving a balance between ultra-high density and small size.

[0026] The adhesive fiber ribbon design of this invention effectively balances the flexibility of the fiber ribbon with the ease of fusion splicing through specific bonding point distribution parameters. It ensures space saving during storage, ease of operation during fusion splicing, and maintains excellent signal transmission performance.

[0027] The high fiber density structured cabling method of the present invention adopts an efficient cabling process. Through standardized steps such as prefabricated terminal direct connection, plug-and-play, and flexible configuration, it effectively simplifies the construction process, significantly improves cabling efficiency, reduces overall cost, and greatly improves the convenience of later maintenance and troubleshooting. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the optical cable protection structure;

[0029] Figure 2 This is a schematic diagram illustrating the principle of high fiber density structured cabling.

[0030] In the diagram, 1-standard connector interface; 2-aramid fiber braided mesh; 3-silicone buffer sleeve; 4-elastic sleeve. Detailed Implementation

[0031] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. After reading this invention, any modifications of the invention in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0032] Example 1:

[0033] An optical cable protection structure of the present invention, such as Figure 1 As shown, at the connection between the high-core-count fiber optic ribbon and the standard connector interface 1, the optical cable protection structure adopts a graded buffer stress relief structure. This graded buffer stress relief structure has three layers from the inside out, including an elastic sleeve 4 sleeved on the outside of the high-core-count fiber optic ribbon, a silicone buffer sleeve 3 sleeved on the elastic sleeve with a thickness that gradually decreases from the standard connector interface end to the high-core-count fiber optic ribbon end, and an aramid fiber braided mesh 2 covering the silicone buffer sleeve. This three-level structure extends from the standard connector interface to the high-core-count fiber optic ribbon from the inside out.

[0034] like Figure 1 As shown, the effective coverage sections of the elastic sleeve 4, silicone buffer sleeve 3, and aramid fiber braided mesh 2 decrease sequentially from the standard connector interface end toward the fiber optic ribbon to achieve a gradient release of stress.

[0035] Furthermore, the elastic sleeve is made of beryllium bronze and contains a spring with a stiffness of 2-3 N / mm.

[0036] Furthermore, the silicone cushioning sleeve has a Shore hardness of 40±5A and its thickness gradually changes from 2mm to 1mm; several retractable dividing ribs can be set inside the silicone cushioning sleeve, and the spacing of the dividing ribs can be adjusted by a rotating adjustment ring, with an adjustment range of 0.2mm-2.4mm.

[0037] Furthermore, the density of the aramid fiber woven mesh is 80 strands / cm², and it is combined with a silicone cushioning sleeve by hot melt adhesive to extend the stress dispersion range to 50mm.

[0038] Furthermore, standard connectors include MPO standard connectors, LC standard connectors, or SC standard connectors.

[0039] Example 2:

[0040] The present invention provides a high fiber density integrated cabling structure, comprising:

[0041] The invention comprises a partially bonded optical fiber ribbon, a flexible sleeve fitted over the partially bonded optical fiber ribbon and employing a fully dry structure, a housing integrating a standard connector interface, and the optical cable protection structure of the present invention, wherein the optical cable protection structure is connected at the connection between the flexible sleeve and the standard connector interface.

[0042] Furthermore, some bonded fiber ribbons have bonding points on their surface formed by a double-sided dispensing process, distributed in a mesh-like pattern. The mesh-like distribution density of the bonding points is 0.5 to 1 point / mm², and the spacing between the bonding points can be 5 cm. This fiber ribbon is easily stored in a coiled form under normal conditions and can be laid flat during fusion splicing. It exhibits excellent attenuation performance: ≤0.34 dB / km in the 1310 nm window and ≤0.21 dB / km in the 1550 nm window.

[0043] Furthermore, the all-dry structure flexible sleeve is an ultra-thin flexible sleeve with a wall thickness reduced to 0.05mm and an outer diameter approximately 10% lower than that of common similar products, achieving a fiber density of up to 6.4 cores / mm². This sleeve uses a material with thermoplastic polyurethane elastomer (TPU) or polyolefin as the matrix, supplemented with low-smoke, halogen-free inorganic additives such as magnesium hydroxide or aluminum hydroxide. It employs a double-layer co-extrusion technology to form a composite structure of a flexible inner layer and a high-strength outer layer. Combined with vacuum sizing technology, the sleeve diameter fluctuation is less than or equal to ±0.05mm, significantly improving the optical cable's bending performance, dimensional stability, and adaptability to extreme temperature changes.

[0044] At the microscopic level, the hard segments in the TPU molecular chain provide strength, while the soft segments impart flexibility; the polyolefin molecular chain is compliant, laying the foundation for the material's flexibility. Inorganic additives, as nano- or micron-sized particles, are uniformly dispersed in the matrix. After surface modification, they form strong interfacial interactions with the matrix, dispersing stress through dispersion reinforcement and acting as nucleating agents to improve polymer crystallinity, thereby synergistically enhancing the material's rigidity and toughness.

[0045] In terms of macroscopic manufacturing processes, the sleeve is prepared using a two-layer co-extrusion technique: the inner layer is made of low-modulus, high-flexibility TPU or polyolefin material to meet the core requirement of flexibility; the outer layer is made of modified materials with high strength and weather resistance (such as TPU or polyolefin with added special additives). Through this process, a good interfacial bond and synergy are formed between the two layers: when the sleeve is under stress, the flexible inner layer can deform freely to absorb most of the deformation energy, while the high-strength outer layer provides protection and restrains the excessive deformation of the inner layer. The mutual diffusion and physical entanglement of molecules at the interface can effectively transfer stress and absorb some energy, jointly improving the sleeve's bending resistance, weather resistance, and extreme temperature change adaptability.

[0046] Furthermore, the manufacturing of the flexible sleeve incorporates vacuum sizing technology. This technology utilizes negative pressure suction within the sizing sleeve to radially expand the softened sheath into a circle while simultaneously cooling it, thereby precisely controlling the sleeve's dimensions. This technology allows the diameter fluctuation of the thin-walled bundled tube to be controlled within ≤±0.05mm, and the outer sheath diameter fluctuation to be less than ±0.25mm. Precise dimensional control avoids stress concentration caused by diameter fluctuations, enhances the sleeve's structural stability, makes its mechanical properties more uniform in different directions, and better resists external force damage.

[0047] Furthermore, the enclosure is an ultra-high-density enclosure, compatible with standard 19-inch racks. The enclosure features an independent pull-out modular design, with modules simultaneously compatible with SC, LC, and MPO connectors, achieving a maximum capacity of 8640 cores per cabinet—three times the density of conventional enclosures. The pull-out module structure facilitates individual cable management and maintenance, while the integrated precision cable management system ensures neat and orderly cabling through layered routing, reducing the risk of signal attenuation.

[0048] Example 3:

[0049] The present invention provides a high fiber density structured cabling method, employing the high fiber density structured cabling of the present invention, the method comprising:

[0050] Outdoor entry involves directly connecting pre-terminated outdoor optical cables to the main distribution frame in the equipment room.

[0051] Indoor interconnection connects pre-terminated indoor optical cables to pre-fabricated ports in the distribution box;

[0052] For device connection, use prefabricated patch cords to connect the patch panel to the device.

[0053] Furthermore, in the outdoor introduction, the number of outdoor optical cables used ranges from 864 to 6912 cores, and both ends are MPO connectors, which are directly connected to the main distribution frame through the MPO-MPO connection method.

[0054] In the indoor interconnection, the prefabricated indoor optical cable has an MPO or LC connector at its end; and / or, in the equipment connection, the prefabricated patch cord used is an LC-LC patch cord, an LC-MPO patch cord, or an MPO-MPO connector.

[0055] Through the above steps, this cabling method achieves zero-splitting operation from outdoors to indoors and all the way to the equipment end, completely eliminating the drawbacks of traditional cabling, such as long splicing construction cycles, high costs, and high dependence on personnel skills. This method fully leverages the advantages of the optical cable protection structure and high fiber density integrated cabling structure of this invention, ultimately achieving a significant improvement in construction efficiency, an effective reduction in overall costs, and providing great convenience for later maintenance and fault location.

[0056] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. An optical cable protection structure, connected at the junction of a high-core-count optical fiber ribbon and a standard connector interface, characterized in that, The optical cable protection structure comprises an elastic sleeve, a silica gel buffer sleeve sleeved outside the elastic sleeve and gradually reducing in thickness from the standard connector interface to the high-core-count optical fiber ribbon, and an aramid fiber woven net wrapped outside the silica gel buffer sleeve, thereby forming a stress relief structure with a graded buffer.

2. The optical cable protection structure of claim 1, wherein, The effective coverage sections of the elastic sleeve, the silica gel buffer sleeve and the aramid fiber woven net from the standard connector interface end to the optical fiber ribbon direction are sequentially reduced to achieve a gradient release of stress.

3. The optical cable protection structure of claim 1, wherein, The elastic sleeve is made of beryllium bronze material and has a spring built therein, and the stiffness of the spring is 2-3 N / mm.

4. The optical cable protection structure of claim 1, wherein, The silica gel buffer sleeve has a Shore hardness of 40±5A and a thickness gradually changing from 2 mm to 1 mm.

5. The optical cable protection structure of claim 1, wherein, The aramid fiber woven net has a density of 80 roots / cm² and is combined with the silica gel buffer sleeve through hot melt glue.

6. A high-fiber-count integrated wiring structure, characterized by comprising: Including A partial bonding type optical fiber ribbon, a flexible sleeve adopting a full dry structure and sleeved outside the partial bonding type optical fiber ribbon, a box body integrated with a standard connector interface, and the optical cable protection structure as claimed in any one of claims 1-5, the optical cable protection structure being connected at the connection between the flexible sleeve and the standard connector interface.

7. The high-fiber-count integrated wiring structure according to claim 6, wherein The partial bonding type optical fiber ribbon has bonding points formed through a double-sided dispensing process and distributed in a mesh shape on the surface of the optical fiber ribbon, and the mesh distribution density of the bonding points is 0.5-1 point / mm².

8. A high fiber count integrated wiring method using the high fiber count integrated wiring structure according to any one of claims 6 to 7, characterized by, The method comprises: Outdoor introduction, directly connecting the prefabricated end outdoor optical cable with the main distribution frame of the machine room; Indoor interconnection, connecting the prefabricated end indoor optical cable with the prefabricated port of the distribution box body; Device connection, connecting the distribution frame with the device end using a prefabricated jumper.

9. The high-fiber- core-density integrated wiring method according to claim 8, wherein In the outdoor introduction, the core count of the outdoor optical cable is 864 cores to 6912 cores, and the two ends of the outdoor optical cable are MPO connectors, and the direct connection with the main distribution frame is achieved through an MPO-MPO connection mode.

10. The high-fiber density comprehensive wiring method according to claim 8, wherein, In the indoor interconnection, the end of the prefabricated end indoor optical cable is an MPO or LC connector; And / or, In the device connection, the prefabricated jumper used is an LC-LC jumper or an LC-MPO jumper or an MPO-MPO connector.

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