High-Density Micro-Bundled Optical Cables Manufactured in China

With the rapid development of information technology, fiber optic cable systems have become increasingly critical in modern communications. As a new type of compact optical cable structure, micro-bundled cables demonstrate remarkable advantages in space efficiency, reduced installation costs, and enhanced transmission performance. This paper investigates process innovations in micro-bundled optical cables aimed at cost reduction and efficiency enhancement. By examining material selection, structural design, manufacturing techniques, and installation methods, it analyzes effective pathways and potential for cost optimization, providing valuable insights for the fiber optic communication industry.

---

I. Research Background

As one of the primary transmission media in modern communication networks, optical fiber technology plays a vital role in achieving high performance and cost-effective systems. With the continual expansion and densification of communication networks, the requirements for cable capacity, physical size, and installation convenience have increased significantly. Owing to their unique structure and performance advantages, micro-bundled optical cables offer an effective solution to these new demands.

In today’s highly competitive market, minimizing CAPEX and OPEX while improving overall network deployment efficiency has become essential for corporate sustainability and growth. Thus, research on process innovation for micro-bundled cables to achieve cost reduction and efficiency enhancement holds substantial practical significance.

---

II. Product Design Solutions

Micro-bundled optical cables are compact, high-density cable products engineered for specific scenarios requiring intensive fiber integration. They are typically categorized into four main types: Air-Blown Micro Cables, Micro-Module Bundled Cables, Sheath + Micro-Module Composite Cables, and Fiber Bundle Armored Cables. The following sections describe the design solutions for each type.

---

Solution 1: Air-Blown Micro Cables

Air-blown micro cables can reach up to 864 fibers with an outer diameter of 9.8 ± 0.3 mm, using 200 μm or 180 μm fibers, arranged in 24-fiber or 36-fiber tubes. The compact design ensures high density, and the sheath is typically made of PE or Nylon.

Air-blown technology uses compressed air to propel cables into microducts, enabling high-density, scalable, and space-efficient network expansion. This solution is particularly advantageous in urban environments where duct space is limited and demand fluctuates.

Key High-Density Features

1. High fiber packing density: Reusable sub-ducts maximize duct occupancy.
2. Scalable deployment: Operators can air-blow micro loose tube cables in phases according to bandwidth demand.
3. Duct resource savings: Smaller diameter and lighter weight allow higher fiber counts with less duct usage.
4. Exceptional fiber density metrics:
   • Single-tube density > 14.17 fibers/mm²
   • SZ-stranded micro cable density > 8.47 fibers/mm²
5. High installation efficiency: Fast blowing speed and long blowing distance.
6. Strong environmental adaptability: Excellent crush resistance and flex performance.
7. Cost-effectiveness: Lower system and installation costs than traditional indoor cables.
8. Special composite loose tubes: Reduce low-temperature shrinkage and enhance cable stability.

---

Solution 2: Micro-Module Bundled Cables

This product supports up to 288 fibers, using 200 μm or 180 μm fibers, with each micro-module containing 24 or 36 tight-buffered fibers. Modules can be SZ-stranded or longitudinally aligned, with an LSZH outer jacket. This structure offers superior module density.

Micro-module technology organizes fibers within miniature tubes to maximize fiber density and routing flexibility—ideal for data centers, metro networks, and access networks.

Cost & Efficiency Advantages

1. Space-saving: Small diameter and lightweight design optimize duct usage.
2. High installation efficiency: Compatible with air-blown installation for semi-automated deployment.
3. Environment-friendly: Significantly reduced use of filling compound.
4. Flexible material: TPE micro-modules are soft and easily tearable for quicker handling.
5. Improved bending performance: Lower risk of micro-module bending-induced fiber breakage.
6. Long service life: Low shrinkage and no fiber protrusion or gel leakage.
7. Scalable network expansion: Future cables can be blown into existing pathways for phased investment.
8. Standardization readiness: Standardizing ultra-high-fiber-count designs facilitates testing and deployment.

---

Solution 3: Sheath + Micro-Module Composite Cables

These cables support up to 864 fibers, with micro-modules inside and an LSZH or PE outer sheath. Each module contains 12 or 24 fibers (200 μm).

This hybrid design significantly increases fiber packing density without increasing outer diameter.

Advantages

1. Higher fiber density: More fibers within a limited cross-section.
2. Duct space optimization: Reduces duct leasing and construction costs.
3. Efficient installation: Automated or semi-automated installation reduces labor intensity.
4. Lower maintenance costs: Fewer splice points due to higher density.

---

Solution 4: Fiber-Bundle Armored Cables

These cables bundle 12 fibers per group, wrapped with polyester yarn using passive pay-off. Maximum tube capacity reaches 72 or 96 fibers. Color-coded combinations (up to 66 variations) improve identification and increase packing density.

Fiber-bundle armored cables are designed for harsh environments requiring rodent resistance, moisture protection, and mechanical robustness.

Advantages

1. Enhanced durability and reliability: Armoring increases resistance to mechanical damage and moisture.
2. Adapted for harsh environments: Suitable for riverbeds, tunnels, seabeds, and other demanding conditions.
3. Reduced fiber reserve: Efficient design minimizes unnecessary slack storage.
4. Higher installation efficiency: Faster deployment with reduced labor costs.
5. Phased capacity expansion: Additional fibers can be blown into mother tubes as needed.
6. Standardized production: Improves manufacturing efficiency and lowers unit cost.
7. Excellent tensile performance: Armoring supports long-distance aerial and direct-buried installation.
8. Long-term cost advantages: Lower maintenance offsets the slightly higher initial investment.

---

III. Technical Features and Advantages

The process innovations of micro-bundled optical cables deliver multiple technical benefits:

1. High fiber density with smaller diameter
   Example: Corning MiniXtend® HD using SMF-28® Ultra 200 fiber provides 288 fibers at a diameter 20% smaller than standard micro cables.
2. FastAccess® Technology for rapid entry
   Eliminates binder yarns and water-blocking materials, increasing access speed by 70%, reducing tube damage risk.
3. Air-blown installation capability
   Enables trenchless deployment, significantly reducing civil engineering costs and urban disruption.
4. Cost savings
   Smaller size = reduced duct occupancy + lower installation and maintenance costs.
5. Easy technological upgrades
   Allows incremental network expansion without replacing the entire cable system.
6. Excellent environmental performance
   Maintains stable operation in temperature extremes and high-moisture environments.
7. Micro-trench installation technology
   Enables network deployment even in areas with no existing duct resources, reducing civil engineering costs dramatically.
8. Process innovations
   Include lean manufacturing, workflow optimization, digital process management, modeling-based design, and simulation-based process validation.

Overall, the innovations in micro-bundled optical cable design significantly enhance network deployment efficiency and reduce total cost of ownership.

---

IV. Conclusion

Process innovation in micro-bundled optical cables holds significant importance and offers broad application potential for reducing costs and improving efficiency. By optimizing materials, innovating structural design, improving manufacturing techniques, and advancing installation methods, the industry can effectively reduce CAPEX and OPEX while enhancing network performance.

Despite challenges such as technical bottlenecks, standardization gaps, and market acceptance barriers, these can be addressed through increased R&D investment, acceleration of industry standardization, and stronger market outreach.

With continuous technological progress and growing demand, micro-bundled optical cables are expected to play an increasingly important role in next-generation optical communication networks, contributing to the construction of high-speed, reliable, and cost-effective communication infrastructure.