Fiber Optic Cable Skeleton Production

Skeleton-type fiber optic cables are produced by embedding optical fibers in a central and peripheral skeleton structure, wrapped and coated to enhance flexibility, bending performance, and durability.

Skeleton-Type Cable Structure

A skeleton-type optical cable consists of a central skeleton and a peripheral skeleton. The peripheral skeleton is pre-filled with optical fibers in a closed pre-wrapping mode and then continuously wrapped around the central skeleton according to a preset pitch, typically ranging from 100 to 1000 mm . This design improves the cable's bending performance and flexibility while maintaining strong support from the central skeleton . The skeleton grooves are usually made from high-modulus materials to prevent deformation under external stress or temperature changes .

Production Method

The production of skeleton-type fiber optic cables involves several key steps:

1. Central Skeleton Formation: The central skeleton is created through extrusion or coating, providing a rigid support structure .
2. Peripheral Skeleton Prefabrication: Optical fibers are embedded in the peripheral skeleton, which is extruded and prefabricated simultaneously .
3. Wrapping and Sheathing: The peripheral skeleton is wrapped around the central skeleton according to a preset pitch, followed by extrusion of a protective sheath layer . This sheath can include polyethylene or other insulating materials to protect against environmental factors.
4. Water-Blocking and Armoring: For dry-type water-blocking cables, water-blocking tapes or gels are added inside the skeleton grooves, and optional metal belts or armoring can be applied for additional mechanical protection .

Materials and Mechanical Considerations

• Skeleton Materials: High-modulus plastics or composites are used for the skeleton to maintain groove integrity and prevent fiber extrusion .
• Optical Fibers: Single-mode or multi-mode fibers are embedded depending on the application, with tight buffering or loose tube designs for protection .
• Sheath Materials: Polyethylene or flame-retardant materials are used for environmental protection .
• Strength Members: Aramid yarns or fiberglass rods may be included to enhance tensile strength and durability .

Quality Control and Testing

During production, precision machinery ensures fiber diameters are maintained within ±1 micron, and attenuation is kept below 0.2 dB/km for single-mode fibers . Final testing includes tensile strength, bending performance, and environmental resistance to ensure long-term reliability .

Applications

Skeleton-type fiber optic cables are widely used in access networks, interoffice connections, and high-density data center applications. Their compact structure, high fiber density, and flexibility make them suitable for both indoor and outdoor installations . In summary, skeleton-type fiber optic cable production combines central and peripheral skeleton design, precise fiber embedding, wrapping, sheathing, and rigorous quality control to produce durable, flexible, and high-performance optical cables suitable for modern communication networks.