The structural design process of the optical cable is the basic factor affecting flexibility and service life. HDMI active optical cable usually adopts a multi-layer composite structure, including fiber core, buffer layer, reinforcement, shielding layer and outer sheath. As the core of signal transmission, the arrangement of the fiber core and the selection of coating materials are crucial. The loose structure is adopted to place the fiber core in the loose tube, which can reduce the direct extrusion of the fiber core by external force and improve flexibility; if the tight sleeve structure is adopted, the thickness and material of the tight sleeve layer can be precisely controlled to make the fiber core closely combined with the external structure, enhance the mechanical properties and extend the service life. The setting of the reinforcement also has a significant impact. High-strength materials such as aramid fiber and Kevlar as reinforcement can provide good tensile properties for the optical cable without adding too much weight, avoid damage to the internal structure caused by external force pulling, and ensure the service life; at the same time, its soft characteristics will not affect the bending performance of the optical cable and maintain good flexibility.
The manufacturing process of the fiber core is directly related to the signal transmission performance and durability of the optical cable. At present, HDMI active optical cable mostly uses single-mode or multi-mode optical fiber as the core. The optical fiber drawing process determines the diameter uniformity and surface quality of the core. High-quality drawing process can ensure that the core diameter error is controlled within a very small range, reduce the loss and distortion during the transmission of optical signals, and indirectly improve the service life of the optical cable. In addition, the coating process of the core should not be ignored. Coating one or more layers of protective materials, such as acrylate, silicone rubber, etc. on the surface of the core can not only enhance the mechanical strength of the core and prevent external mechanical damage, but also isolate the erosion of environmental factors such as moisture and chemicals, and extend the service life of the core. At the same time, the flexibility of the coating layer also affects the overall bending performance of the optical cable. Appropriate coating materials and processes can keep the optical cable still flexible and stable when it is frequently bent.
The processing technology of the outer sheath has a direct impact on the flexibility and service life of the HDMI active optical cable. The selection of the outer sheath material and the molding process are the key. Common outer sheath materials include polyvinyl chloride (PVC), polyurethane (PU), low smoke zero halogen (LSZH), etc. The PVC outer sheath has a lower cost, but its flexibility and weather resistance are relatively poor; the PU outer sheath has excellent wear resistance, oil resistance and flexibility, can adapt to complex use environments, and extend the service life of the optical cable; the LSZH outer sheath is outstanding in environmental protection and flame retardancy, and is suitable for places with high safety requirements. In the molding process, the temperature, pressure and speed control of the extrusion process directly affect the thickness uniformity and surface quality of the outer sheath. The precise extrusion process can make the outer sheath tightly wrap the internal structure, provide good mechanical protection, while maintaining appropriate softness and improving the flexibility of the optical cable. If the outer sheath processing technology is improper, defects such as uneven thickness and bubbles may occur, causing the optical cable to be easily damaged during use and shortening its service life.
The manufacturing and assembly process of the connector is crucial to the performance of the HDMI active optical cable. The connector is a key component for realizing the conversion of optical signals and electrical signals. Its manufacturing accuracy and assembly quality affect the stability and reliability of signal transmission. In the connector manufacturing process, precision injection molding is used to mold the connector shell. High-precision molds and injection molding parameter control can ensure the accurate size of the shell and fit closely with the internal components to prevent poor signal contact due to looseness, which in turn affects the service life. The assembly process of components such as optoelectronic conversion chips and circuit boards inside the connector also needs to be strictly controlled. The use of surface mount technology (SMT) for component welding can ensure welding quality, reduce problems such as cold soldering and short circuits, and improve the stability and durability of the connector. In addition, the connection process between the connector and the optical cable is also critical. The optical cable and the connector are firmly connected by hot melting, crimping, etc. to ensure the sealing and mechanical strength of the connection part, avoid loose connection due to external pulling or bending, and affect the service life and flexibility of the optical cable.
The shielding process is related to flexibility and service life while ensuring the performance of the HDMI active optical cable. In order to prevent the influence of external electromagnetic interference on the transmission of optical signals, a shielding layer is usually set in the optical cable structure. Common shielding methods include metal braided mesh, metal foil, etc. The weaving density and process of the metal braided mesh shielding layer directly affect the shielding effect and flexibility. High-density weaving can provide better shielding performance, but may reduce the flexibility of the optical cable; reasonable control of the weaving density and the use of soft metal materials can maintain the flexibility of the optical cable while ensuring the shielding effect. The metal foil shielding layer needs to be wrapped tightly around the internal structure of the optical cable through a precise bonding process to ensure that the shielding layer is complete and gapless, while not affecting the bending performance of the optical cable. A good shielding process can not only improve the stability of signal transmission, reduce signal attenuation and distortion caused by interference, but also protect internal components from damage by the electromagnetic environment and extend the service life of the optical cable.
The quality inspection process in the production process is an important link to ensure the flexibility and service life of the HDMI active optical cable. From the inspection of raw materials entering the factory to the inspection of finished products leaving the factory, every link must be strictly controlled. During the raw material inspection stage, the physical and chemical properties of the fiber core, outer sheath material, connector, etc. are tested to ensure that the materials meet the quality standards and lay the foundation for product performance. During the production process, the diameter, tension, signal transmission performance, etc. of the optical cable are monitored in real time through online detection equipment to promptly discover and correct problems in the production process and prevent unqualified products from entering the next process. In the finished product inspection stage, various performance tests such as bending test, tensile test, high and low temperature test, etc. are carried out to simulate the actual use environment and check whether the flexibility and service life of the optical cable meet the standards. Only through strict quality inspection process can we ensure that the produced HDMI active optical cable meets user needs in terms of flexibility and service life.
The later packaging and storage process will also affect the performance of HDMI active optical cable. Reasonable packaging methods can protect the optical cable from mechanical damage and environmental factors during transportation and storage. Use soft buffer material to wrap the optical cable to avoid direct contact with hard objects and prevent scratches and extrusion damage. At the same time, the packaging material should have good moisture-proof and dust-proof properties to prevent moisture and dust from entering the interior of the optical cable and affecting its performance and service life. During storage, the optical cable should be stored in a dry and ventilated environment, away from direct sunlight and high temperature and high humidity environment, to prevent aging of the outer sheath material and degradation of the fiber core performance. Good packaging and storage technology can maintain the good performance of the optical cable before delivery and use, indirectly extending its service life in the hands of users and maintaining stable flexibility.
