Environment-friendly light hollow-core optical fiber cable and manufacturing method thereof

Abstract

The invention discloses an environment-friendly light-weight hollow-core optical fiber cable and a manufacturing method thereof, and relates to the technical field of optical fiber communication, the key points of the technical scheme are that the environment-friendly light-weight hollow-core optical fiber cable comprises a cable core and an outer sheath wrapping the cable core, the cable core is formed by twisting at least one optical fiber sleeve and a plurality of filling ropes, at least one hollow-core optical fiber is arranged in the optical fiber sleeve, and the filling ropes are arranged in the hollow-core optical fiber; the filling rope comprises a hollow pipe body and a plurality of solid water blocking sections, and the solid water blocking sections are formed by curing a foaming material and are arranged in an inner cavity of the hollow pipe body at preset intervals. On the basis of ensuring the structural integrity and water-blocking performance of the optical cable, the material consumption and the product weight are reduced, and the overall flexibility of the optical cable is optimized, so that the optical cable is particularly suitable for advanced hollow-core optical fiber application scenes sensitive to weight, environmental protection and stress.

Description

Technical Field

[0001] This invention relates to the field of optical fiber communication technology, and more specifically, to an environmentally friendly, lightweight hollow optical fiber cable and its manufacturing method. Background Technology

[0002] With the rapid development of communication technology, optical fiber cables, as the "nerves" of information transmission, face increasingly stringent performance and environmental protection requirements. Traditional solid or continuous foamed filler ropes in optical cables mainly serve as structural supports and water-blocking agents, but they have the following drawbacks: First, the extensive use of plastic materials results in a heavy optical cable, which is not conducive to high-density cabling and energy conservation and emission reduction. Second, their flexibility usually differs from that of the optical fiber sheath, leading to uneven overall flexibility after stranding. This can easily generate localized stress when bent or twisted, which is particularly detrimental to hollow optical fibers with their precise internal structure and sensitivity to micro-bending, potentially affecting their transmission performance. Furthermore, traditional filler ropes consume a large amount of material, which contradicts the current industrial trend of green environmental protection and carbon emission reduction.

[0003] To reduce the weight of optical cables, existing technologies have attempted to use hollow structures filled with ropes, but these typically present new challenges. For example, while completely hollow tubular structures can achieve weight reduction, it is often difficult to balance mechanical strength and water-blocking performance. Industry standards usually have specific requirements for the water-blocking performance of optical cables, such as ensuring that water cannot penetrate within any 3-meter length under a constant water pressure of 1 meter water column. How to construct an effective barrier that meets these key water-blocking indicators without significantly increasing weight and material usage, while simultaneously ensuring excellent and uniform flexibility of the optical cable, has become a pressing technical challenge in this field.

[0004] Therefore, a new solution is needed to address this problem. Summary of the Invention

[0005] In view of this, the purpose of the present invention is to provide an environmentally friendly lightweight hollow optical fiber cable and its manufacturing method, which can reduce material consumption and product weight while ensuring the structural integrity and water-blocking performance of the optical cable, and optimize the overall flexibility of the optical cable, making it particularly suitable for advanced hollow optical fiber applications that are sensitive to weight, environmental protection and stress.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is: an environmentally friendly lightweight hollow optical fiber cable, comprising a cable core and an outer sheath covering the cable core. The cable core is formed by twisting at least one optical fiber tube with multiple filler ropes. At least one hollow optical fiber is disposed inside the optical fiber tube. The filler rope comprises a hollow tube body and multiple solid water-blocking sections. The solid water-blocking sections are formed by solidifying foam material and are disposed at preset intervals in the internal cavity of the hollow tube body.

[0007] Preferably, the preset spacing is no more than 3 meters.

[0008] Preferably, the foaming material is any one of polyurethane, epoxy resin, or polyethylene foamable polymer material.

[0009] Preferably, the material of the hollow tube is the same as or similar to the material of the optical fiber sheath.

[0010] Preferably, the length of the solid water-blocking strip is 2mm-10mm.

[0011] A method for manufacturing an environmentally friendly lightweight hollow optical fiber cable, used to manufacture any of the aforementioned environmentally friendly lightweight hollow optical fiber cables, includes a method for manufacturing the filler rope, the method for manufacturing the filler rope comprising the following steps:

[0012] S1. The hollow tube body is prepared by extrusion molding and cooling;

[0013] S2. Move the hollow tube body and pass through a rolling device, the rolling device being provided with at least one needle that can penetrate the tube wall of the hollow tube body.

[0014] S3. When the needle pierces the wall of the hollow tube, a quantitative amount of the foaming material is injected into the internal cavity of the hollow tube.

[0015] S4. The fluid-like foamed material is foamed and solidified in situ in the internal cavity of the hollow tube to form the solid water-blocking section.

[0016] The solid water-blocking section fills and seals the pinhole left by the insertion pin on the wall of the hollow tube.

[0017] Preferably, the manufacturing method of the environmentally friendly lightweight hollow optical fiber cable further includes the following steps:

[0018] S5. Provide at least one fiber optic sleeve with a hollow fiber inside.

[0019] S6. Twist the optical fiber sheath together with the multiple filler ropes obtained in steps S1 to S4 to form a cable core.

[0020] S7. An outer sheath is extruded over the cable core to produce the environmentally friendly lightweight hollow optical fiber cable.

[0021] Preferably, in step S2, the rotation direction of the rolling device is adapted to the forward direction of the hollow tube, so that the pin periodically pierces the tube wall of the hollow tube.

[0022] Preferably, there are multiple pins arranged in a circular array along the circumferential direction of the rolling device, and the preset spacing is determined by the spacing between adjacent pins and the relative speed of the rolling device and the hollow tube.

[0023] Preferably, in step S3, the fluid foaming material is any one of unfoamed polyurethane, unfoamed epoxy resin, or unfoamed polyethylene composition.

[0024] Compared with existing technologies, the advantages of the environmentally friendly lightweight hollow optical fiber cable and its manufacturing method disclosed in this invention are: 1. By setting solid sections only at key water-blocking points, it is only necessary to ensure that there is one solid water-blocking section within a preset interval, thereby achieving maximum hollowing of the filling rope body while ensuring water-blocking performance, and significantly reducing weight; 2. Through the above-mentioned setting, the amount of materials used is greatly reduced, reducing resource consumption and carbon emissions in the production process from the source, which is more in line with current green and environmental protection requirements; 3. The hollow structure makes the overall flexibility of the filling rope consistent with that of the optical fiber sheath, making its flexibility uniform after twisting, effectively avoiding stress concentration, and playing a supporting and filling role while also protecting the hollow optical fiber. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of an environmentally friendly lightweight hollow optical fiber cable according to an embodiment of this application;

[0027] Figure 2 This is a schematic diagram of the rolling device, the insert pin, and the filling rope according to an embodiment of this application.

[0028] Figure 3 This is a schematic flowchart illustrating the manufacturing method of the environmentally friendly lightweight hollow optical fiber cable according to an embodiment of this application.

[0029] The numbers or letters in the attached diagram represent the names of the corresponding components:

[0030] 1. Fiber optic sleeve; 2. Filler rope; 21. Hollow tube body; 22. Solid water-blocking section; 3. Hollow fiber; 4. Central reinforcing member; 5. Outer sheath; 6. Rolling device; 7. Insert. Detailed Implementation

[0031] The technical solution of the present invention will now be clearly and completely described through specific embodiments. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0032] Please see Figure 1 and Figure 2 This application provides an environmentally friendly lightweight hollow optical fiber cable, comprising a cable core and an outer sheath 5 covering the cable core. The cable core is formed by twisting at least one optical fiber tube 1 and multiple filler ropes 2 around a central reinforcing member 4 to form a round structure. The central reinforcing member 4 can specifically be a fiber-reinforced plastic rod. At least one hollow optical fiber 3 is disposed inside the optical fiber tube 1. The filler rope 2 includes a hollow tube body 21 and multiple solid water-blocking sections 22. The solid water-blocking sections 22 are formed by curing foam material and are arranged at preset intervals in the internal cavity of the hollow tube body 21. The outer peripheral wall of the cured water-blocking section is tightly fitted to the inner peripheral wall of the hollow tube body 21. The filler rope 2 has a periodic alternating structure of "hollow section - solid water-blocking section 22 - hollow section" along its length. The preset interval is no more than 3 meters, the purpose of which is to ensure that the solid water-blocking section 22 of the optical cable can meet the general industry test conditions, that is, under the pressure of 1 meter water column, the water blocking within a 3-meter section is effective.

[0033] In this embodiment, the foaming material is any one of polyurethane, epoxy resin, or polyethylene foamable polymer material.

[0034] In this embodiment, the material of the hollow tube 21 is the same as or similar to that of the optical fiber sheath 1. Specifically, both the hollow tube 21 and the optical fiber sheath 1 can be selected from the same polyolefin material such as low-density polyethylene (LDPE), medium-density polyethylene (MDPE), or polypropylene (PP), or other materials with similar mechanical and thermal properties, without any specific limitations. This configuration allows the hollow tube 21 and the optical fiber sheath 1 to deform collaboratively under bending, torsion, and other stresses after being stranded into a cable, effectively avoiding internal stress concentration caused by differences in stiffness between components, and providing a uniform and favorable mechanical environment for the hollow optical fiber 3.

[0035] In this embodiment, the length of the solid water-blocking strip is 2mm-10mm, specifically 2mm, 4mm, 5mm, 6mm, 8mm, or 10mm, as long as its length is sufficient to achieve an effective sealing and water-blocking function.

[0036] Please see Figure 1 , Figure 2 and Figure 3This invention also discloses a method for manufacturing an environmentally friendly lightweight hollow optical fiber cable, used to manufacture any environmentally friendly lightweight hollow optical fiber cable, including a method for manufacturing a filler rope 2, the method for manufacturing the filler rope 2 comprising the following steps:

[0037] S1. The hollow tube 21 is extruded by an extruder and cooled by a cooling water tank.

[0038] S2. The hollow tube 21 is moved and passes through a rolling device 6. The rolling device 6 is equipped with at least one pin 7 that can pierce the wall of the hollow tube 21. The rotation direction of the rolling device 6 is adapted to the forward direction of the hollow tube 21, so that the pin 7 periodically pierces the wall of the hollow tube 21. Furthermore, there are multiple pins 7 arranged in a circular array along the circumference of the rolling device 6. The preset spacing is determined by the spacing between adjacent pins 7 and the relative speed of the rolling device 6 and the hollow tube 21. By adjusting the relative speed, the preset spacing of the solid water-blocking section 22 on the filling rope 2 can be adjusted accordingly.

[0039] S3. When the needle 7 pierces the wall of the hollow tube 21, a quantitative amount of fluid foaming material is injected into the internal cavity of the hollow tube 21.

[0040] S4. The fluid-like foamed material is foamed and solidified in situ within the internal cavity of the hollow tube 21 to form a solid water-blocking section 22. The internal pressure during the entire foaming process is controlled within the elastic limit of the foamed material, thus preventing permanent expansion of the outer diameter of the hollow tube 21. At the same time, the pressure generated by the foaming expansion causes some material to flow back, completely sealing the tiny pinholes left by the insertion pin 7 and ensuring the integrity of the filling rope 2.

[0041] S5. Provide at least one fiber optic sleeve 1 with a hollow fiber 3 inside.

[0042] S6. Twist the optical fiber sheath 1 together with the multiple filler ropes 2 obtained in steps S1 to S4 to form a cable core.

[0043] S7. An outer sheath 5 is extruded over the cable core to produce an environmentally friendly, lightweight hollow optical fiber 3 cable.

[0044] The hollow tube 21 can be moved by a traction wheel, and a semi-circular groove is provided below the rolling device 6 to support and allow the hollow tube 21 to move.

[0045] The aforementioned rolling device 6 includes a frame, a servo geared motor mounted on the frame, and the output shaft of the servo geared motor driving a rotating disk to rotate. The rotating disk is equipped with a storage box for storing foaming material and a metering pump for pumping the foaming material from the storage box. The metering pump is connected to a corresponding insertion pin 7 via a pipeline. An electric slip ring is provided between the servo geared motor and the rotating disk to stably supply power to the metering pump during continuous rotation of the rotating disk. The device also includes a PLC controller, with the servo geared motor and metering pump electrically connected to the PLC controller.

[0046] When the rolling device 6 is working, the PLC controller controls the servo geared motor to drive the rotating disk to rotate, and simultaneously supplies power to the metering pump on the disk through the slip ring. When the needle 7 on the rotating disk rotates to pierce the wall of the hollow tube 21, the PLC controller triggers the corresponding metering pump. The metering pump performs a fixed stroke, injecting a preset dose of foaming material directly into the cavity inside the tube through the needle 7. After injection, the metering pump is turned off, and the needle 7 leaves with the rotating disk. This process is repeated cyclically as the rotating disk rotates, thereby forming periodic foaming material injection points with precise spacing and consistent dosage inside the hollow tube 21.

[0047] The hollow tube 21 is driven forward by a traction wheel mechanism. Below the rolling device 6, there is a guide groove for supporting and guiding the movement of the hollow tube 21. The cross-sectional shape of the guide groove matches the outer periphery of the hollow tube 21, for example, it is V-shaped or arc-shaped.

[0048] It is understood that the aforementioned rolling device 6 and its specific configuration are merely exemplary devices for implementing the manufacturing method of the filler rope 2 of the present invention, and are not necessary limitations on the technical solution claimed in this application. The core of this application lies in protecting the manufacturing method itself, which includes the steps of "needle injection and controlled in-situ foaming," and this method can also be implemented by other devices that can achieve the same function.

[0049] In this embodiment, in step S3, the fluid foaming material is any one of unfoamed polyurethane, unfoamed epoxy resin, or unfoamed polyethylene composition.

[0050] In summary, this invention achieves maximum hollowing of the main body of the filling rope 2 by setting solid segments only at key water-blocking points, ensuring that there is only one solid water-blocking segment 22 within a preset interval. This significantly reduces weight while maintaining water-blocking performance. This design greatly reduces material usage, minimizing resource consumption and carbon emissions during production, thus aligning with current green and environmentally friendly requirements. The hollow structure makes the overall flexibility of the filling rope 2 consistent with that of the optical fiber sheath 1, ensuring uniform flexibility after twisting. This effectively avoids stress concentration and, while providing support and filling, also protects the hollow optical fiber.

[0051] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An environmentally friendly lightweight hollow optical fiber cable, comprising a cable core and an outer sheath covering the cable core, wherein the cable core is formed by twisting at least one optical fiber tube with multiple filler ropes, and at least one hollow optical fiber is disposed inside the optical fiber tube, characterized in that: The filling rope includes a hollow tube and multiple solid water-blocking sections. The solid water-blocking sections are formed by solidifying foamed material and are arranged at preset intervals in the internal cavity of the hollow tube.

2. The environmentally friendly lightweight hollow optical fiber cable according to claim 1, characterized in that: The preset spacing is no more than 3 meters.

3. The environmentally friendly lightweight hollow optical fiber cable according to claim 1, characterized in that: The foaming material is any one of polyurethane, epoxy resin, or polyethylene foamable polymer material.

4. The environmentally friendly lightweight hollow optical fiber cable according to claim 1, characterized in that: The hollow tube is made of the same or similar material as the optical fiber sheath.

5. The environmentally friendly lightweight hollow optical fiber cable according to claim 1, characterized in that: The length of the solid water-blocking strip is 2mm-10mm.

6. A method for manufacturing an environmentally friendly lightweight hollow optical fiber cable, used to manufacture the environmentally friendly lightweight hollow optical fiber cable as described in any one of claims 1 to 5, characterized in that, The method for manufacturing the filling rope includes the following steps: S1. The hollow tube body is prepared by extrusion molding and cooling; S2. Move the hollow tube body and pass through a rolling device, the rolling device being provided with at least one needle that can penetrate the tube wall of the hollow tube body. S3. When the needle pierces the wall of the hollow tube, a quantitative amount of the foaming material is injected into the internal cavity of the hollow tube. S4. The fluid-like foamed material is foamed and solidified in situ in the internal cavity of the hollow tube to form the solid water-blocking section. The solid water-blocking section fills and seals the pinhole left by the insertion pin on the wall of the hollow tube.

7. The method for manufacturing the environmentally friendly lightweight hollow optical fiber cable according to claim 6, characterized in that: The manufacturing method of the environmentally friendly lightweight hollow optical fiber cable also includes the following steps: S5. Provide at least one fiber optic sleeve with a hollow fiber inside. S6. Twist the optical fiber sheath together with the multiple filler ropes obtained in steps S1 to S4 to form a cable core. S7. An outer sheath is extruded over the cable core to produce the environmentally friendly lightweight hollow optical fiber cable.

8. The method for manufacturing the environmentally friendly lightweight hollow optical fiber cable according to claim 6, characterized in that: In step S2, the rotation direction of the rolling device is adapted to the forward direction of the hollow tube, so that the pin periodically pierces the tube wall of the hollow tube.

9. The method for manufacturing the environmentally friendly lightweight hollow optical fiber cable according to claim 6, characterized in that: The pins are configured as a plurality of pins, which are arranged in a circular array along the circumference of the rolling device. The preset spacing is determined by the spacing between adjacent pins and the relative speed of the rolling device and the hollow tube.

10. The method for manufacturing the environmentally friendly lightweight hollow optical fiber cable according to claim 6, characterized in that: In step S3, the fluid foaming material is any one of unfoamed polyurethane, unfoamed epoxy resin, or unfoamed polyethylene composition.

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