Miniaturized high-reliability special optical cable and preparation method thereof

Abstract

The application discloses a kind of miniaturization high reliability special optical cable and preparation method thereof, including outer sheath and at least one optical fiber unit and at least two reinforcing elements arranged in it, and the outer setting of optical fiber unit has bionic gradient self-repairing composite layer.The application realizes the significant reduction of cable outer diameter, super bending resistance and long-term dynamic reliability simultaneously under the premise of not relying on special optical fiber, especially suitable for high-density wiring scene.The preparation method of the application is based on precise co-extrusion and topological optimization positioning, and the process is efficient, which is conducive to industrialization.

Description

Technical Field

[0001] This invention belongs to the field of special optical cable technology, specifically relating to a miniaturized high-reliability special optical cable and its preparation method. Background Technology

[0002] With the development of cloud computing and 5G technologies, the interconnection density within and between communication equipment has increased dramatically. Within the limited spaces of data center racks and base station antenna systems, the outer diameter, bending radius, and weight of traditional optical cables have become major bottlenecks for increasing cabling density. The industry urgently needs to significantly reduce the diameter of optical cables (miniaturization) while maintaining, and even enhancing, their mechanical properties, bending resistance, and long-term dynamic reliability.

[0003] Currently, to improve optical cable performance, the industry's main technical approaches include relying on specialty optical fibers, optimizing the sheath structure, adding mechanical reinforcements, and introducing self-healing concepts. However, these solutions all have limitations: specialty optical fibers are expensive and only address the fiber itself; multi-layer buffer structures cannot adapt to dynamic stress due to their fixed modulus ratio; eccentric designs offer unstable protection; adding reinforcements increases cable diameter; and self-healing mechanisms based on physical action suffer from low repair strength and slow repair speed.

[0004] In summary, existing technologies employ static, homogeneous materials and simple geometric arrangements to cope with dynamic and complex stress environments. This makes it difficult to simultaneously achieve mechanical reliability, bending resistance, and long-term stability in optical cables during miniaturization. Therefore, there is an urgent need for an integrated solution capable of dynamically responding to external stress and actively maintaining performance. Summary of the Invention

[0005] To address the problems in the prior art, the present invention aims to provide a miniaturized, highly reliable special optical cable and its manufacturing method. While achieving significant miniaturization of the outer diameter, it possesses excellent resistance to bending, lateral pressure, and tensile stress, as well as long-term dynamic reliability. It is particularly suitable for application scenarios with stringent requirements for space utilization, bending performance, and long-term reliability, such as high-density data centers, 5G fronthaul networks, and complex building cabling.

[0006] To achieve the above objectives and technical effects, the technical solution adopted by this invention is as follows: A miniaturized high-reliability special optical cable includes an outer sheath and at least one optical fiber unit and at least two reinforcing elements disposed therein, wherein a biomimetic gradient self-healing composite layer is disposed outside the optical fiber unit.

[0007] Furthermore, the biomimetic gradient self-healing composite layer contains self-healing microcapsules and photonic lattice microcavity units.

[0008] Furthermore, the wall material of the self-healing microcapsule is urea-formaldehyde resin or melamine resin, and its core material is encapsulated with liquid diallyl disulfide repair agent. The photonic lattice microcavity unit is a solid or hollow silica microsphere with an average particle size of 1-10 μm, which is periodically arranged in an approximately hexagonal close-packed topology in the biomimetic gradient self-healing composite layer.

[0009] Furthermore, the biomimetic gradient self-healing composite layer includes an inner bonding buffer layer, an intermediate functional gradient layer, and an outer constraint protection layer, which are co-extruded together from the inside to the outside. The self-healing microcapsules and photonic lattice microcavity units are uniformly dispersed in the intermediate functional gradient layer.

[0010] Furthermore, the self-healing microcapsule has a mass percentage of 5-10% in the intermediate functional gradient layer, and the photonic lattice microcavity unit has a mass percentage of 3-8% in the intermediate functional gradient layer.

[0011] Furthermore, the material of the inner adhesive buffer layer is a thermoplastic elastomer with an elastic modulus of 50-150 MPa; The elastic modulus of the intermediate functional gradient layer changes continuously from the inside to the outside within the range of 200-800 MPa. The material of the outer constraint protective layer is an engineering plastic with an elastic modulus greater than or equal to 1 GPa.

[0012] Furthermore, the optical fiber unit is a G.652.D single-mode optical fiber; The reinforcing element is an aramid yarn bundle or a glass fiber reinforced plastic rod; The thickness of the outer sheath is 0.3-0.8 mm.

[0013] This invention also discloses a method for preparing a miniaturized, high-reliability special optical cable, comprising the following steps: S1. Material preparation and fiber optic alignment: Prepare the raw materials that constitute the inner bonding buffer layer, the intermediate functional gradient layer and the outer constraint protection layer, and arrange the optical fiber units neatly. S2. Multi-channel gradient co-extrusion molding: The raw materials of the three layers of inner bonding buffer layer, intermediate functional gradient layer and outer constraint protection layer are melted separately and extruded simultaneously through a co-extrusion die, so that the melt of the three layers of raw materials is fused and coated with the optical fiber unit according to the preset modulus gradient. After cooling, an integrated core functional body is formed. The core functional body includes the optical fiber unit and the inner bonding buffer layer, intermediate functional gradient layer and outer constraint protection layer that are sequentially coated on its outside from the inside. S3. Positioning Integration: The core functional body obtained in step S2 is asymmetrically positioned and fixed with at least two reinforcing elements to form a cable core prefabricated body. S4. Extruded outer sheath: The cable core obtained in step S3 is prefabricated and then extruded to form an outer sheath, thereby producing the miniaturized high-reliability special optical cable.

[0014] Furthermore, in step S2, the co-extrusion die is a co-extrusion die with at least three independent flow channels and one gradient composite flow channel. One independent flow channel contains raw material with an inner bonding buffer layer, one independent flow channel contains raw material with an intermediate functional gradient layer, and one independent flow channel contains raw material with an outer constraint protection layer. The melts of the raw materials of the inner bonding buffer layer, the intermediate functional gradient layer, and the outer constraint protection layer are mutually impregnated and fused in the gradient composite flow channel to coat the optical fiber unit.

[0015] Furthermore, in step S3, the core functional body obtained in step S2 and at least two reinforcing elements are asymmetrically positioned and fixed using a topology-optimized positioning mold. The topology-optimized positioning mold is connected to the online monitoring unit. The online monitoring unit monitors the shape and position of the core functional body in real time, analyzes and processes the data, and controls the topology-optimized positioning mold to achieve precise asymmetric positioning between the core functional body and the reinforcing element.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1) It achieves dynamic active protection and extended service life, with a high internal micro-crack repair rate and good long-term reliability; 2) It pioneered a new paradigm of light-force synergistic design, directly assisting in reducing bending losses from a physical perspective; 3) It achieves ultimate space efficiency and performance breakthrough, exhibiting superior bending and compressive strength with smaller cable diameters; 4) The preparation process is advanced, has good compatibility with existing production lines, and has industrialization potential. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the structure of the biomimetic gradient self-healing composite layer of the present invention. Detailed Implementation

[0018] The present invention will now be described in detail so that its advantages and features can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0019] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0020] like Figure 1-2 As shown, the present invention discloses a miniaturized high-reliability special optical cable, including an outer sheath 4 and at least one optical fiber unit 1 and at least two reinforcing elements 3 disposed therein. A biomimetic gradient self-healing composite layer 2 is disposed outside the optical fiber unit 1. The core functional body composed of the optical fiber unit 1 and the biomimetic gradient self-healing composite layer 2 is arranged non-centrally symmetrically with respect to the reinforcing elements 3 on the cross-section of the optical cable, forming a biomimetic lever mechanical model, which preferentially guides the bending stress to the side of the reinforcing elements.

[0021] In some implementations, the non-centrally symmetrical arrangement specifically means that at least two reinforcing elements 3 are arranged parallel to each other and symmetrically on one side of the optical cable cross-section, while the core functional body is arranged on the other side.

[0022] In some implementations, the biomimetic gradient self-healing composite layer 2 is an integrated structure formed by one-time co-extrusion, with the elastic modulus continuously increasing from the inside to the outside, forming an efficient stress transmission path.

[0023] In some specific embodiments, the biomimetic gradient self-healing composite layer 2 includes an inner adhesive buffer layer 2-1, an intermediate functional gradient layer 2-2, and an outer constraint protection layer 2-5, which are co-extruded and bonded from the inside to the outside.

[0024] In some specific embodiments, the material of the inner adhesive buffer layer 2-1 is a thermoplastic elastomer with an elastic modulus of 50-150 MPa.

[0025] In some specific implementations, the elastic modulus of the intermediate functional gradient layer 2-2 changes continuously from the inside to the outside in the range of 200-800 MPa.

[0026] In some specific implementations, the material of the outer constraint protective layer 2-5 is an engineering plastic with an elastic modulus greater than or equal to 1 GPa.

[0027] In some specific implementations, self-healing microcapsules 2-3 and photonic lattice microcavity units 2-4 are uniformly dispersed in the intermediate functional gradient layer 2-2, which respectively realize active chemical repair of cracks and macro-bending loss suppression based on the photonic bandgap principle, and have the functions of dynamic stress buffering, active crack repair and light leakage suppression.

[0028] In some specific embodiments, the wall material of the self-healing microcapsules 2-3 is urea-formaldehyde resin or melamine resin, and its core material is encapsulated with liquid diallyl disulfide repair agent.

[0029] In some specific embodiments, the photonic lattice microcavity unit 2-4 is a solid or hollow silica microsphere with an average particle size of 1-10 μm, which is periodically arranged in an approximately hexagonal close-packed topology in the intermediate functional gradient layer 2-2.

[0030] In some specific embodiments, the self-healing microcapsules 2-3 constitute 5-10% of the mass of the intermediate functional gradient layer 2-2.

[0031] In some specific implementations, the photonic lattice microcavity unit 2-4 has a mass percentage of 3-8% in the intermediate functional gradient layer 2-2.

[0032] In some specific implementations, fiber unit 1 is a G.652.D single-mode fiber.

[0033] In some specific embodiments, the reinforcing element 3 is an aramid yarn bundle or a glass fiber reinforced plastic rod.

[0034] In some specific embodiments, the thickness of the outer sheath 4 is 0.3-0.8 mm.

[0035] This invention also discloses a method for preparing a miniaturized, high-reliability special optical cable, comprising the following steps: S1. Material preparation and fiber optic alignment: Prepare the raw materials that constitute the inner bonding buffer layer 2-1, the intermediate functional gradient layer 2-2 and the outer constraint protection layer 2-5, and arrange the optical fiber units 1 neatly. S2. Multi-channel gradient co-extrusion molding: The raw materials of the three layers, namely the inner bonding buffer layer 2-1, the intermediate functional gradient layer 2-2 and the outer constraint protection layer 2-5, are melted separately and extruded simultaneously through a co-extrusion die. The melt of the three layers of raw materials is fused and coated with the optical fiber unit 1 according to the preset modulus gradient. After cooling, an integrated core functional body is formed. The core functional body includes the optical fiber unit 1 and the inner bonding buffer layer 2-1, the intermediate functional gradient layer 2-2 and the outer constraint protection layer 2-5, which are sequentially coated on its outside from the inside. S3. Positioning Integration: The core functional body obtained in step S2 is asymmetrically positioned and fixed with at least two reinforcing elements 3 to form a cable core prefabricated body. S4. Extruded outer sheath 4: The miniaturized high-reliability special optical cable is obtained by extruding and covering the cable core prefabricated body 4 in step S3.

[0036] In step S2, the co-extrusion die is a co-extrusion die with three independent flow channels and one gradient composite flow channel. One independent flow channel contains the raw material of the inner bonding buffer layer 2-1, one independent flow channel contains the raw material of the intermediate functional gradient layer 2-2, and one independent flow channel contains the raw material of the outer constraint protection layer 2-5. The melt of the raw materials of the inner bonding buffer layer 2-1, the intermediate functional gradient layer 2-2, and the outer constraint protection layer 2-5 is mutually impregnated and fused in the gradient composite flow channel to cover the optical fiber unit 1.

[0037] In step S3, the core functional body obtained in step S2 and at least two reinforcing elements 3 are asymmetrically positioned and fixed using a topology optimization positioning mold. The topology-optimized positioning mold is connected to the online monitoring unit. The online monitoring unit monitors the shape and position of the core functional body in real time, analyzes and processes the data, and controls the topology-optimized positioning mold to achieve precise asymmetric positioning between the core functional body and the reinforcing element 3.

[0038] This invention, without relying on special optical fibers, achieves significant reduction in optical cable outer diameter, superior bending resistance, and long-term dynamic reliability through synergistic innovation in materials and structure, making it particularly suitable for high-density cabling scenarios. The fabrication method of this invention is based on precision co-extrusion and topology optimization positioning, resulting in a highly efficient process that is conducive to industrialization.

[0039] Example 1

[0040] like Figure 1-2 As shown, a miniaturized high-reliability special optical cable includes an outer sheath 4 and an optical fiber unit 1 and two reinforcing elements 3 disposed therein. A biomimetic gradient self-healing composite layer 2 is disposed outside the optical fiber unit 1. The core functional body composed of the optical fiber unit 1 and the biomimetic gradient self-healing composite layer 2 is arranged non-centrally symmetrically with respect to the reinforcing elements 3 on the cross-section of the optical cable, forming a biomimetic lever mechanical model, which preferentially guides the bending stress to the side of the reinforcing elements.

[0041] Fiber unit 1 uses 8-core G.652.D single-mode fiber.

[0042] The biomimetic gradient self-healing composite layer 2 includes an inner adhesive buffer layer 2-1, an intermediate functional gradient layer 2-2, and an outer constraint protective layer 2-5, which are co-extruded and bonded from the inside to the outside.

[0043] The inner bonding buffer layer 2-1 is made of SEBS-based material with a Shore hardness of 70A.

[0044] The intermediate functional gradient layer 2-2 is made of polyurethane matrix, with the modulus gradually changing from 250MPa at the inner edge to 700MPa at the outer edge. It contains 8% by mass of self-healing microcapsules of urea-formaldehyde resin wall material (average particle size 50μm) and 5% by mass of solid silica microspheres (average diameter 3μm).

[0045] The outer constraint protective layer 2-5 is made of PBT material.

[0046] The reinforcing element 3 uses two bundles of 600 Denier aramid yarn.

[0047] The outer sheath 4 is 0.4 mm thick and is made of low-smoke halogen-free flame-retardant polyolefin.

[0048] The core functional unit is elliptical in shape, measuring 1.8mm × 3.2mm.

[0049] The additional loss at 1550nm wavelength is 0.028dB after 10 turns of the Φ15mm mandrel; it is undamaged when laterally compressed to 3800N / 10cm; the additional loss changes by <0.02dB after 5000 repeated bending cycles, and micro-CT confirms the effectiveness of the self-repair function.

[0050] Example 2

[0051] like Figure 1-2 As shown, a miniaturized high-reliability special optical cable includes an outer sheath 4 and an optical fiber unit 1 and two reinforcing elements 3 disposed therein. A biomimetic gradient self-healing composite layer 2 is disposed outside the optical fiber unit 1. The core functional body composed of the optical fiber unit 1 and the biomimetic gradient self-healing composite layer 2 is arranged non-centrally symmetrically with respect to the reinforcing elements 3 on the cross-section of the optical cable, forming a biomimetic lever mechanical model, which preferentially guides the bending stress to the side of the reinforcing elements.

[0052] Fiber unit 1 uses 24-core G.652.D single-mode fiber in a 2×12 microstrip structure.

[0053] The biomimetic gradient self-healing composite layer 2 includes an inner adhesive buffer layer 2-1, an intermediate functional gradient layer 2-2, and an outer constraint protective layer 2-5, which are co-extruded and bonded from the inside to the outside.

[0054] The inner bonding buffer layer 2-1 is made of weather-resistant modified polyolefin.

[0055] The intermediate functional gradient layer 2-2 is made of polyurethane matrix, with the modulus gradually changing from 250MPa at the inner edge to 700MPa at the outer edge. It contains self-healing microcapsules (average particle size 50μm) of 8% melamine resin wall material and solid silica microspheres (average diameter 3μm) of 3% melamine resin wall material.

[0056] The outer constraint protective layer 2-5 is made of PBT material.

[0057] The reinforcing element 3 consists of two glass fiber reinforced plastic rods with a diameter of 1.0 mm.

[0058] The outer sheath 4 is 0.8 mm thick and is made of high-density polyethylene.

[0059] The core functional unit measures 2.5mm × 6.0mm.

[0060] Comparative Example 1 A commercially available 12-core double-sheathed "bending-resistant" optical cable with an outer diameter of 6.0mm was selected for comparison.

[0061] Test 1 (bending radius 30mm): Comparative Example 1 additional loss 0.08dB; after adjusting the outer diameter of Example 1 product to 6.0mm, the additional loss was 0.015dB.

[0062] Test 2 (repeated bending 1000 times): The optical cable loss change in Example 1 was <0.01dB, and the appearance was undamaged; the optical cable loss change in Comparative Example 1 was >0.05dB, the sheath showed wrinkles, and ultrasonic testing revealed interlayer gaps.

[0063] This invention breaks through the technical bottleneck of miniaturization and high reliability by deeply synergistic innovation in materials and structure, and provides a high-performance optical cable solution with long-term dynamic stability.

[0064] Any parts or structures not specifically described in this invention can be made using existing technologies or products, and will not be elaborated upon here.

[0065] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A miniaturized, high-reliability special optical cable, characterized in that, It includes an outer sheath and at least one optical fiber unit and at least two reinforcing elements disposed therein, wherein the optical fiber unit is provided with a biomimetic gradient self-healing composite layer.

2. The miniaturized high-reliability special optical cable according to claim 1, characterized in that, The biomimetic gradient self-healing composite layer contains self-healing microcapsules and photonic lattice microcavity units.

3. The miniaturized high-reliability special optical cable according to claim 2, characterized in that, The wall material of the self-healing microcapsule is urea-formaldehyde resin or melamine resin, and its core material is encapsulated with liquid diallyl disulfide repair agent. The photonic lattice microcavity unit is a solid or hollow silica microsphere with an average particle size of 1-10 μm, which is periodically arranged in an approximately hexagonal close-packed topology in the biomimetic gradient self-healing composite layer.

4. The miniaturized high-reliability special optical cable according to claim 2, characterized in that, The biomimetic gradient self-healing composite layer includes an inner bonding buffer layer, an intermediate functional gradient layer, and an outer constraint protection layer, which are co-extruded together from the inside to the outside. The self-healing microcapsules and photonic lattice microcavity units are uniformly dispersed in the intermediate functional gradient layer.

5. A miniaturized, high-reliability special optical cable according to claim 4, characterized in that, The self-healing microcapsules have a mass percentage of 5-10% in the intermediate functional gradient layer, and the photonic lattice microcavity units have a mass percentage of 3-8% in the intermediate functional gradient layer.

6. A miniaturized, high-reliability special optical cable according to claim 4, characterized in that, The material of the inner adhesive buffer layer is a thermoplastic elastomer with an elastic modulus of 50-150 MPa; The elastic modulus of the intermediate functional gradient layer changes continuously from the inside to the outside within the range of 200-800 MPa. The material of the outer constraint protective layer is an engineering plastic with an elastic modulus greater than or equal to 1 GPa.

7. The miniaturized high-reliability special optical cable according to claim 1, characterized in that, The optical fiber unit is a G.652.D single-mode optical fiber; The reinforcing element is an aramid yarn bundle or a glass fiber reinforced plastic rod; The thickness of the outer sheath is 0.3-0.8 mm.

8. A method for fabricating a miniaturized, highly reliable special optical cable, characterized in that, Includes the following steps: S1. Material preparation and fiber optic alignment: Prepare the raw materials that constitute the inner bonding buffer layer, the intermediate functional gradient layer and the outer constraint protection layer, and arrange the optical fiber units neatly. S2. Multi-channel gradient co-extrusion molding: The raw materials of the three layers of inner bonding buffer layer, intermediate functional gradient layer and outer constraint protection layer are melted separately and extruded simultaneously through a co-extrusion die, so that the melt of the three layers of raw materials is fused and coated with the optical fiber unit according to the preset modulus gradient. After cooling, an integrated core functional body is formed. The core functional body includes the optical fiber unit and the inner bonding buffer layer, intermediate functional gradient layer and outer constraint protection layer that are sequentially coated on its outside from the inside. S3. Positioning Integration: The core functional body obtained in step S2 is asymmetrically positioned and fixed with at least two reinforcing elements to form a cable core prefabricated body. S4. Extruded outer sheath: The cable core obtained in step S3 is prefabricated and then extruded to form an outer sheath, thereby producing the miniaturized high-reliability special optical cable.

9. The method for manufacturing a miniaturized high-reliability special optical cable according to claim 8, characterized in that, In step S2, the co-extrusion die is a co-extrusion die with at least three independent flow channels and one gradient composite flow channel. One independent flow channel contains raw material with an inner bonding buffer layer, one independent flow channel contains raw material with an intermediate functional gradient layer, and one independent flow channel contains raw material with an outer constraint protection layer. The melt of the raw materials of the inner bonding buffer layer, the intermediate functional gradient layer, and the outer constraint protection layer is mutually impregnated and fused in the gradient composite flow channel to coat the optical fiber unit.

10. The method for fabricating a miniaturized, high-reliability special optical cable according to claim 8, characterized in that, In step S3, the core functional body obtained in step S2 and at least two reinforcing elements are asymmetrically positioned and fixed using a topology optimization positioning mold; The topology-optimized positioning mold is connected to the online monitoring unit. The online monitoring unit monitors the shape and position of the core functional body in real time, analyzes and processes the data, and controls the topology-optimized positioning mold to achieve precise asymmetric positioning between the core functional body and the reinforcing element.

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