Composite cable for utility tunnel and manufacturing method therefor

Abstract

The present invention relates to a composite cable for a utility tunnel. The composite cable comprises an optical cable unit, a communication control cable unit, and a power cable unit; water-blocking filling ropes are interposed among the optical cable unit, the communication control cable unit, and the power cable unit; the optical cable unit, the communication control cable unit, and the power cable unit are stranded together, and then an integrated protective layer is wrapped around the outside to form a cable. When in use, the composite cable of the present invention is provided with an optical cable unit, a communication control cable unit and a power cable unit, and thus simultaneously has the functions of information control, network interconnection and power transmission; and when used in an underground utility tunnel, the composite cable not only can provide power, but also has signal control and network transmission capabilities, and also has fireproof and waterproof capabilities; moreover, the product is environmentally-friendly and safe.

Description

Composite cables for integrated utility tunnels and their manufacturing method Technical Field

[0001] This invention relates to the technical field of cables, specifically to composite cables for integrated utility tunnels and their preparation methods, and more particularly to composite cables for underground urban integrated utility tunnels and their preparation methods. Background Technology

[0002] In existing technologies, fiber optic integrated cables combine optical cables, power cables, and communication cables into one unit, saving significant space and construction costs. This meets the needs of my country's rapidly developing communication network. Underground utility tunnels are public tunnels built underground in cities for the centralized laying of municipal pipelines such as power, communication, broadcasting, and water supply.

[0003] The construction, management, and safe operation of urban underground utility tunnels need to ensure that their operation and management level can adapt to the needs of economic and social development, enhance emergency disaster prevention capabilities, provide support for operation and maintenance, emergency disaster prevention, and public services, and improve the city's comprehensive carrying capacity and the needs of urbanization.

[0004] Therefore, there is an urgent need in the market for a composite cable that can be comprehensively applied to the construction of underground urban utility tunnels. Summary of the Invention

[0005] The purpose of this invention is to provide an improved composite cable for integrated utility tunnels and its preparation method. Through structural and process improvements, the product simultaneously possesses information control, network interconnection, and power transmission functions, while exhibiting outstanding fire resistance, good corrosion resistance, and low cost.

[0006] To achieve the above objectives, the technical solution of the present invention is: a composite cable for integrated utility tunnels, characterized in that: the composite cable includes an optical cable unit, a communication control cable unit, and a power cable unit, with water-blocking filler rope filling between the optical cable unit, the communication control cable unit, and the power cable unit; after the optical cable unit, the communication control cable unit, and the power cable unit are twisted together, an external integrated protective layer is wrapped around them to form a cable.

[0007] A power cable unit consists of several power conductor cores, which are wrapped together by an insulating tape. Water-blocking ropes are filled between adjacent power conductor cores. The water-blocking ropes are mixed with refractory aggregate particles, and a sheath is extruded onto the surface of the insulating tape.

[0008] The optical cable unit consists of a non-metallic reinforcing member located in the center and several optical fiber bundles arranged around the non-metallic reinforcing member. Each optical fiber bundle contains 2-12 optical fibers. The middle part of the non-metallic reinforcing member is an elastic bending part, and several reinforcing support parts are embedded around the elastic bending part.

[0009] The communication control cable unit includes several communication conductor cores. Each communication conductor core includes two single cores. The two single cores are wrapped with polyester tape and copper-plastic composite tape to form the communication conductor cores. Water-blocking yarn is filled between the single cores. Several communication conductor cores are wrapped with water-blocking tape to form a cable. Water-blocking yarn is filled between the communication conductor cores.

[0010] Preferably, the optical cable unit, the communication control cable unit, and the power cable unit are filled with water-blocking filler rope, and the comprehensive protective layer consists of water-blocking tape, fire-resistant layer, corrugated metal sheath, and outer sheath from the inside out.

[0011] Furthermore, the non-metallic reinforcing member is cylindrical, with the elastic bending part in the middle made of rubber, polyurethane or nylon, and four reinforcing support parts are evenly embedded around the elastic bending part, which are made of fiber-reinforced composite plastic.

[0012] Furthermore, the volume ratio of the supporting part to the flexible bending part is 1:2-5.

[0013] Furthermore, the power cable unit includes four power conductor cores, which are made of copper conductors wrapped with mica tape and a ceramicized polyolefin fireproof insulation layer with a thickness of 1.0-2.5mm.

[0014] The water-blocking rope is made of inorganic non-combustible expanded fiberglass rope, the insulation tape is made of halogen-free high flame-retardant tape with a thickness of 0.15-0.25mm, and the sheath is made of low-smoke halogen-free sheath material extruded with a thickness of 1.2-1.8mm.

[0015] The volume ratio of refractory aggregate particles to water-blocking rope is 1:8-16.

[0016] Furthermore, the refractory aggregate particles are made by mixing alumina hollow spheres with a diameter of 0.2-5mm and zirconia hollow spheres with a diameter of 1-0.15mm, with the mass ratio of alumina hollow spheres to zirconia hollow spheres being 1:0.8-1.5.

[0017] Furthermore, the optical cable unit is equipped with 5 optical fiber bundles, which are cabled by wrapping water-blocking tape. Water-blocking yarn is filled between the 5 optical fiber bundles, and aramid yarn is wrapped around the water-blocking tape. The aramid yarn is then extruded with an anti-tracking sheath material with a thickness of 1-1.5mm.

[0018] Furthermore, in the communication control cable unit, each single core is made of oxygen-free copper wire extruded with a ceramicized polyolefin fire-retardant insulation layer, the thickness of which is 0.8-1.5mm. Two single cores are wrapped with double-layer polyester tape to form a cable. The copper-plastic composite tape includes a copper tape layer and a plastic layer, with the copper tape layer placed close to the core. Three communication conductor cores are wrapped with water-blocking tape to form the communication control cable unit. The water-blocking tape is extruded with a low-smoke halogen-free sheath material, the thickness of which is 1.0-1.5mm.

[0019] A method for preparing composite cables for integrated utility tunnels, characterized in that the preparation method includes the following steps: a) Manufacturing a power cable unit, the power cable unit comprising four power conductor cores, the power conductor cores being made of copper conductors wrapped with mica tape and a ceramicized polyolefin fire-retardant insulation layer, the thickness of the ceramicized polyolefin fire-retardant insulation layer being 1.0-2.5mm; the water-blocking rope is made of inorganic non-combustible expanded glass fiber rope, the insulation tape is made of halogen-free high flame-retardant wrapping tape, the thickness of the wrapping tape being 0.15-0.25mm, and the sheath is made of low-smoke halogen-free sheath material extruded, the sheath thickness being 1.2-1.8mm; b) Manufacturing an optical cable unit, the optical cable unit having five optical fiber bundles and non-metallic reinforcing members, the five optical fiber bundles being cabled by wrapping water-blocking tape, the spaces between the five optical fiber bundles being filled with water-blocking yarn, the water-blocking tape being wrapped with aramid yarn, and the aramid yarn being extruded with an anti-tracking sheath material, the sheath thickness being 1-1.5mm; c) Manufacturing a communication control cable unit, in which a single wire The core is made of oxygen-free copper wire extruded with a ceramicized polyolefin fire-retardant insulation layer, the thickness of which is 0.8-1.5mm. Two single cores are wrapped with double-layer polyester tape to form a cable. The copper-plastic composite tape includes a copper tape layer and a plastic layer, with the copper tape layer placed close to the core. Three communication conductor cores are wrapped with water-blocking tape to form a communication control cable unit. The water-blocking tape is extruded with a low-smoke halogen-free sheath material, with a sheath thickness of 1.0-1.5mm. d. The power cable unit is one core, and the optical cable unit... As one core, the communication control cable consists of three cores twisted clockwise to the right to form a cable. The gaps between the three cores are filled with water-blocking rope, and then wrapped tightly with water-blocking tape with a thickness of 0.2mm. e. A ceramicized polyolefin fireproof insulation layer is extruded on the surface of the water-blocking tape as a fire-resistant layer with a thickness of 1.5-3.0mm. A corrugated metal sheath is wrapped around the surface of the fire-resistant layer, and a low-smoke halogen-free sheath material is extruded on the corrugated metal sheath as an outer sheath with a thickness of 1.5-2.5mm.

[0020] Compared with the prior art, the technical solution of the present invention not only improves the overall technical solution, but also includes many improvements in details. Specifically, it has the following beneficial effects:

[0021] 1. The improved solution of the present invention comprises an optical cable unit, a communication control cable unit, and a power cable unit. Water-blocking filler rope is filled between the optical cable unit, the communication control cable unit, and the power cable unit. After the optical cable unit, the communication control cable unit, and the power cable unit are twisted together, an external comprehensive protective layer is wrapped to form a cable, so that the product has information control, network interconnection and power transmission functions at the same time, and has outstanding fire resistance, good waterproof and corrosion resistance.

[0022] 2. In the technical solution of the present invention, the power cable unit includes several power conductor cores, which are wrapped into a cable by insulating tape. Water-blocking ropes are filled between adjacent power conductor cores. The water-blocking ropes are mixed with fire-resistant aggregate particles. The insulating tape is covered with an extruded sheath. It has excellent fireproof and fire-resistant properties and outstanding aging resistance. It can ensure the smooth operation of power and communication in the event of a fire, and buy valuable time for personnel escape and fire rescue.

[0023] 3. In the structure of the present invention, the optical cable unit is composed of a non-metallic reinforcing member located at the center and several optical fiber bundles arranged around the non-metallic reinforcing member. Each optical fiber bundle contains 2-12 optical fibers. The middle part of the non-metallic reinforcing member is an elastic bending part. Several reinforcing support parts are embedded around the elastic bending part to ensure the flexibility and strength of the optical cable unit and to ensure the safe use of the optical cable unit under extreme high temperature and high humidity environments.

[0024] 4. In the technical solution of the present invention, the communication control cable unit includes several communication conductor cores, each communication conductor core includes two single cores, and the two single cores are wrapped with polyester tape and copper-plastic composite tape to form the communication conductor cores. Water-blocking yarn is filled between the single cores. Several communication conductor cores are wrapped with water-blocking tape to form a cable, and water-blocking yarn is filled between the communication conductor cores. It has a good anti-electromagnetic shielding effect, plays a blocking role, and makes the core wire electromagnetically coupled only to the shielding layer. At the same time, it is resistant to high temperature and suitable for use in different environments.

[0025] 5. The present invention has a reasonable layout and convenient process. The resulting cable has excellent fire resistance, waterproof and corrosion resistance, and is suitable for the construction and application of underground urban utility tunnels. Attached Figure Description

[0026] Figure 1 is a cross-sectional structural diagram of the present invention.

[0027] Figure 2 is a structural schematic diagram of an embodiment of the present invention.

[0028] Figure 3 is a schematic diagram of the structure of the power cable unit of the present invention.

[0029] Figure 4 is a schematic diagram of the optical cable unit of the present invention.

[0030] Figure 5 is a schematic diagram of the communication control cable unit of the present invention.

[0031] Reference numerals: 1 Optical cable unit, 2 Communication control cable unit, 3 Power cable unit, 4 Water-blocking filler rope, 5 Main cable water-blocking tape, 6 Fire-resistant layer, 7 Corrugated metal sheath, 8 Outer sheath; 11 Optical fiber bundle tube, 12 Non-metallic reinforcing member, 13 Optical cable unit water-blocking tape, 14 Water-blocking yarn, 15 Aramid yarn, 16 Tracking resistant sheath material; 121 Elastic bending section, 122 Reinforcing support section; 21 Communication conductor core, 22 Single core, 23 Polyester tape, 24 Copper-plastic composite tape, 25 Oxygen-free copper wire, 26 Water-blocking wrapping tape, 27 Low-smoke halogen-free sheath material, 28 Single core insulation layer; 31 Power conductor core, 32 Water-blocking rope, 33 Sheath, 34 Mica tape, 35 Ceramicized polyolefin fireproof insulation layer, 36 Insulating tape, 37 Copper conductor. Detailed Implementation

[0032] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] This invention provides a composite cable for integrated utility tunnels, as shown in Figure 1. Its difference from existing technologies lies in the following: the composite cable comprises an optical cable unit, a communication control cable unit, and a power cable unit. Water-blocking filler rope 4 is inserted between the optical cable unit, communication control cable unit, and power cable unit. After the optical cable unit, communication control cable unit, and power cable unit are twisted together, an external integrated protective layer is wrapped around them to form a cable. The power cable unit comprises several power conductor cores 31, which are wrapped together by an insulating tape 36. Water-blocking rope 32 is inserted between adjacent power conductor cores. The water-blocking rope contains refractory aggregate particles, and a sheath 33 is extruded onto the surface of the insulating tape.

[0034] The optical cable unit 1 consists of a non-metallic reinforcing member 12 located in the center and several optical fiber bundles 11 arranged around the non-metallic reinforcing member. Each optical fiber bundle contains 2-12 optical fibers. The middle part of the non-metallic reinforcing member is an elastic bending part 121, and several reinforcing support parts 122 are embedded around the elastic bending part 121.

[0035] The communication control cable unit includes several communication conductor cores. Each communication conductor core includes two single cores. The two single cores are wrapped with polyester tape and copper-plastic composite tape to form the communication conductor cores. Water-blocking yarn is filled between the single cores. Several communication conductor cores are wrapped with water-blocking tape to form a cable. Water-blocking yarn is filled between the communication conductor cores.

[0036] In use, the composite cable of the present invention is equipped with an optical cable unit, a communication control cable unit, and a power cable unit, and has information control, network interconnection and power transmission functions. When used in underground integrated pipe corridors, it can not only provide power, but also has signal control and network transmission capabilities, as well as fireproof and waterproof capabilities. The product is environmentally friendly and safe.

[0037] Example 1

[0038] In this embodiment, the composite cable includes an optical cable unit 1, a communication control cable unit 2, and a power cable unit 3. Water-blocking filler rope 4 is inserted between the optical cable unit, the communication control cable unit, and the power cable unit. After the optical cable unit, the communication control cable unit, and the power cable unit are twisted together, an external comprehensive protective layer is wrapped around them to form a cable. The power cable unit 3 includes several power conductor cores 31, which are wrapped together by an insulating tape 36. Water-blocking rope 32 is inserted between adjacent power conductor cores. The water-blocking rope contains refractory aggregate particles, and a sheath 33 is extruded onto the surface of the insulating tape. The optical cable unit 1 consists of a non-metallic fiber located at the center. The cable unit consists of a reinforcing member 12 and several fiber optic bundles 11 arranged around the non-metallic reinforcing member. Each fiber optic bundle contains 2-12 optical fibers. The middle part of the non-metallic reinforcing member is an elastic bending part 121, and several reinforcing support parts 122 are embedded around the elastic bending part. The communication control cable unit includes several communication conductor cores 21. Each communication conductor core includes two single cores 22. The two single cores are wrapped with polyester tape 23 and copper-plastic composite tape 24 to form a communication conductor core. Water-blocking yarn is filled between the single cores. Several communication conductor cores are wrapped with water-blocking tape to form a cable, and water-blocking yarn is filled between the communication conductor cores.

[0039] Specifically, water-blocking filler rope 4 is used to fill the gaps between the optical cable unit, communication control cable unit, and power cable unit. The comprehensive protective layer consists of, from the inside out, a main cable water-blocking strip 5, a fire-resistant layer 6, a corrugated metal sheath 7, and an outer sheath 8. The optical cable unit consists of a non-metallic reinforcing member located in the center and five optical fiber bundles surrounding the non-metallic reinforcing member. Each optical fiber bundle contains 2-12 optical fibers arranged inside a loose tube. The outer diameter of the loose tube is 2.0-2.5 mm, and the wall thickness is ≥0.35 mm.

[0040] Furthermore, the non-metallic reinforcing member 12 is cylindrical, with a central elastic bending portion 121 made of rubber, polyurethane, or nylon. Four reinforcing support portions 122 are evenly embedded around the elastic bending portion 121, and these support portions are made of fiber-reinforced composite plastic. The elastic bending portion and the reinforcing support portions can be connected via a snap-fit ​​mechanism. The elastic bending portion has a dovetail groove or a wedge-shaped groove, and the reinforcing support portions have protrusions that mate with the dovetail groove or wedge-shaped groove.

[0041] Furthermore, the reinforcing support section here can be set in sections, that is, each reinforcing support section is composed of several thin reinforcing support strips that are disconnected at both ends. This has the advantage of saving material and improving the flexibility of the wire.

[0042] Meanwhile, the volume ratio of the reinforcing support to the elastic bending part is 1:2-5, preferably 1:2.8, which can achieve a certain degree of bending flexibility while maintaining toughness and strength, ensuring that the optical fiber is not easily broken during use, and is also easy to bend and deploy.

[0043] Furthermore, the power cable unit includes four power conductor cores 31, which are made of copper conductors 37 wrapped with mica tape 34 and a ceramicized polyolefin fireproof insulation layer 35. The thickness of the ceramicized polyolefin fireproof insulation layer is 1.0-2.5mm, preferably 1.5mm. The water-blocking rope is made of inorganic non-combustible expanded glass fiber rope, the insulation tape 36 is made of halogen-free high flame-retardant tape with a thickness of 0.15-0.25mm, and the sheath is made of low-smoke halogen-free sheath material extruded with a thickness of 1.2-1.8mm. The volume ratio of refractory aggregate particles to water-blocking rope is 1:8-16.

[0044] It adopts a round, tightly compressed copper conductor with a dense conductor structure. Under the same conductor cross-sectional area, the outer diameter of the conductor is reduced by about 10% after compression, thereby reducing the outer diameter of the product and facilitating installation and laying.

[0045] It adopts a double fireproof insulation layer structure. The inner layer is wrapped with overlapping mineral insulating fireproof tape, with a tape thickness of 0.14mm. The calcined mica tape is guaranteed not to break down within 90 minutes at a temperature of 850-900℃ and a voltage of 600-1000V; it has stable chemical properties, excellent acid and alkali resistance, excellent aging resistance, and excellent environmental performance, containing no toxic or harmful components and not producing toxic gases at high temperatures. The mica tape is extruded with a new type of fireproof ceramicized polyolefin insulation material, with a thickness ranging from 1.0mm to 2.5mm depending on the specifications. In addition to the characteristics of ordinary polyolefin insulation materials, the ceramicized polyolefin fireproof insulation material also has excellent fireproof and flame-retardant properties. Under flame, it forms a hard ceramic-like shell that does not melt or drip in a fire environment (650℃-3000℃) and has excellent heat and fire insulation effects, ensuring uninterrupted power and communication in the event of a fire, buying valuable time for personnel escape and fire rescue.

[0046] Specifically, the refractory aggregate particles here are composed of hollow alumina spheres with a diameter of 0.2-5mm and hollow zirconia spheres with a diameter of 1-0.15mm. The mass ratio of the hollow alumina spheres to the hollow zirconia spheres is 1:0.8-1.5, preferably 1:1.2. In practice, after mixing the two types of refractory aggregate particles, they can be mixed and placed between the water-blocking ropes.

[0047] Alternatively, slots can be made along the water-blocking rope, and a portion of the mixed refractory aggregate particles can be embedded into the slots for better results. The alumina hollow spheres mentioned here are a new type of high-temperature insulation material with an α-Al₂O₃ microcrystalline form. Using alumina hollow spheres as the main body, various shapes of products can be manufactured, with a maximum service temperature of 1800 degrees Celsius. Zirconia hollow spheres are a high-grade refractory raw material with a particularly strong melting point, which can broaden the temperature range for viscosity changes. They have good thermal stability, improve the glaze's crack resistance, and due to their high chemical inertness, enhance the glaze's chemical stability and acid and alkali resistance. They also act as an opacifier.

[0048] Furthermore, a portion of the water-blocking rope can be grooved and filled with refractory aggregate particles, while another portion of the water-blocking rope is wound into a ball. The two types of water-blocking ropes are mixed in a 1:1 ratio and then filled, which can achieve better results.

[0049] Example 2

[0050] In this embodiment, the composite cable includes an optical cable unit, a communication control cable unit, and a power cable unit. Water-blocking filler ropes are inserted between the optical cable unit, communication control cable unit, and power cable unit. After the optical cable unit, communication control cable unit, and power cable unit are twisted together, an external comprehensive protective layer is wrapped around them to form a cable. The power cable unit includes several power conductor cores, which are wrapped together by insulating tape. Water-blocking ropes are inserted between adjacent power conductor cores, and the water-blocking ropes contain fire-resistant aggregate particles. A sheath is extruded onto the surface of the insulating tape. The optical cable unit consists of a centrally located... The cable consists of a non-metallic reinforcing member and several fiber optic bundles surrounding the non-metallic reinforcing member. Each fiber optic bundle contains 2-12 fiber cores. The central part of the non-metallic reinforcing member is an elastic bending section, and several reinforcing support sections are embedded around the elastic bending section. The communication control cable unit includes several communication conductor cores. Each communication conductor core includes two single cores. The two single cores are wrapped with polyester tape and copper-plastic composite tape to form the communication conductor cores. Water-blocking yarn is filled between the single cores. Several communication conductor cores are wrapped with water-blocking tape to form a cable, and water-blocking yarn is filled between the communication conductor cores.

[0051] Specifically, the optical cable unit has 5 optical fiber bundle tubes 11. The 5 optical fiber bundle tubes are bundled into a cable by wrapping the optical cable unit with water-blocking tape 13. Water-blocking yarn 14 is filled between the 5 optical fiber bundle tubes. Aramid yarn 15 is wrapped around the water-blocking tape. The aramid yarn is extruded with an anti-tracking sheath material 16. The sheath thickness is 1-1.5mm.

[0052] In the communication control cable unit, the single core is made of oxygen-free copper wire 25 extruded with a ceramicized polyolefin fireproof insulation layer 28. The thickness of the single core insulation layer 28 is 0.8-1.5mm. Two single cores are wrapped with double-layer polyester tape to form a cable. The copper-plastic composite tape includes a copper tape layer and a plastic layer. The copper tape layer is set close to the core. Three communication conductor cores are wrapped with water-blocking tape 26 to form a communication control cable unit. The water-blocking tape 26 is extruded with low-smoke halogen-free sheath material 27 with a sheath thickness of 1.0-1.5mm.

[0053] Furthermore, the conductor material is oxygen-free copper wire with a diameter of 0.5-4mm. 2 Depending on the application conditions, Class 1, Class 2, or Class 5 conductors can be used. A ceramicized polyolefin insulating material is extruded over the conductor. This insulating material possesses excellent insulation properties, with a volume resistivity ≥2×10¹⁵ Ω·cm. It forms a hard, solid shell quickly; under flame and extinguishing conditions at 350-1600℃, it can be fired into a hard, armor-like shell. The higher the temperature and the longer the firing time, the harder the resulting ceramic-like armor. The residue is pure ceramic inorganic material. During the ablation process, the ceramic-like armor forms dense, honeycomb-like micropores, and a "ceramic enamel" film forms on the surface, providing excellent fire resistance, heat insulation, and temperature insulation. It can pass the spray and vibration tests required for Class A (950-1100℃ × 180min) and the highest level CWZ of BS6387. The insulated cores are distinguished by numbers or colors.

[0054] Then, the core groups are twisted together. Each core group consists of two single cores, twisted together with a twist pitch of 20-30mm. Each pair of twisted core groups is distinguished by a different colored tape. Two layers of 0.05mm thick polyester tape are wrapped around the outside of the twisted cores, with an overlap rate of not less than 20%, as a shielding layer.

[0055] Each pair of twisted wire cores is wrapped with a 0.1mm thick copper-plastic composite tape, with the copper layer in the tape being at least 0.06mm thick. During wrapping, the copper tape layer is close to the wire core, and the plastic layer is the outermost layer. The copper-plastic composite tape acts as a shield, protecting the communication wire core from electromagnetic interference. The shielding layer acts as a barrier, ensuring that the core wires only have electromagnetic coupling with the shielding layer, while the distributed capacitance between the shielding layer and external metal objects is irrelevant to the core wires. The wire cores are arranged clockwise, with the outermost layer twisted to the right. During cabling, water-blocking yarn is filled between the cores, and two layers of 0.2mm thick water-blocking tape are wrapped around the cores and secured tightly to ensure a rounded cable.

[0056] Example 3

[0057] The method for preparing composite cables for integrated utility tunnels according to the present invention includes the following steps: a) Fabricating power cable units, each power cable unit comprising four power conductor cores, the power conductor cores being made of copper conductors wrapped with mica tape and a ceramicized polyolefin fire-retardant insulation layer, the thickness of the ceramicized polyolefin fire-retardant insulation layer being 1.0-2.5mm; the water-blocking rope is made of inorganic non-combustible expanded glass fiber rope, and the insulation tape is made of halogen-free high flame-retardant wrapping tape, the thickness of the wrapping tape being 0.15-0.25mm. m. The sheath is extruded from low-smoke halogen-free sheath material, with a thickness of 1.2-1.8mm; b. Fabrication of optical cable units: Each optical cable unit has 5 fiber optic bundles and non-metallic reinforcing members. The 5 fiber optic bundles are cabled by wrapping water-blocking tape. Water-blocking yarn is filled between the 5 fiber optic bundles. Aramid yarn is wrapped around the water-blocking tape, and an anti-tracking sheath material is extruded over the aramid yarn. The sheath thickness is 1-1.5mm; c. Fabrication of communication control cable units: In the communication control cable unit, the single core is made of oxygen-free... The cable is made by extruding copper wire with a ceramicized polyolefin fire-retardant insulation layer, the thickness of which is 0.8-1.5mm. Two single-core wires are wrapped with double-layer polyester tape to form a cable. The copper-plastic composite tape includes a copper tape layer and a plastic layer, with the copper tape layer positioned close to the core. Three communication conductor cores are wrapped with water-blocking tape to form a communication control cable unit. The water-blocking tape is extruded with a low-smoke halogen-free sheath material, with a sheath thickness of 1.0-1.5mm. d. The power cable unit is considered as one core, and the optical cable unit is considered as... One core, the communication control cable is used as one core, and three cores are twisted together clockwise to the right to form a cable. The gaps between the three cores are filled with water-blocking rope, and at the same time, they are wrapped tightly with water-blocking tape with a thickness of 0.2mm; e, a ceramicized polyolefin fireproof insulation layer is extruded on the surface of the water-blocking tape as a fire-resistant layer with a thickness of 1.5-3.0mm. A corrugated metal sheath is wrapped around the surface of the fire-resistant layer, and a low-smoke halogen-free sheath material is extruded on the corrugated metal sheath as an outer sheath with a thickness of 1.5-2.5mm.

[0058] Specifically, in the cabling process, the power cable unit is used as one core, the optical cable unit is used as one core, and the communication control cable is used as one core. The three cores are twisted together clockwise to the right. The gaps between the three cores are filled with water-blocking rope, and at the same time, they are wrapped tightly with water-blocking tape with a thickness of 0.2mm.

[0059] Then, a fire-resistant layer is extruded onto the combined core of the cable after cabling. The fire-resistant layer is made of ceramicized polyolefin material extruded onto the heat insulation layer. The ceramicized polyolefin material can self-extinguish and not propagate flame when burned horizontally, with an oxygen index of ≥35. Under conditions of 350-1600℃ with and without flame, it does not melt, drip, or fall off, and will not cause secondary fires. It can be fired into a hard ceramic-like armor. The higher the temperature and the longer the firing time, the harder the ceramic-like armor becomes. The residue is ceramic inorganic material, with a residue content of more than 80%. The ceramic-like armor can form honeycomb-like ceramic micropores, which can play a very good role in fire insulation and heat insulation. Its excellent flame retardancy can also play a very good role in fire prevention.

[0060] The cable employs a corrugated metal sheath, welded using argon arc welding. The sheath is made of copper strip, with thicknesses of 0.5mm and 0.6mm selected depending on the specifications. The corrugated metal sheath serves several purposes: firstly, it improves the cable's mechanical properties, enhances impact resistance, and provides excellent bending performance; secondly, the argon arc welding creates a sealed environment within the sheath, providing excellent waterproofing, corrosion and insect protection, and effectively protecting the internal insulation of the cable core in the event of outer sheath damage, ensuring normal cable operation; and thirdly, the copper sheath acts as a shield, effectively blocking external electromagnetic interference and providing overall shielding.

[0061] The outer sheath is extruded onto the metal sheath using an extrusion method, with a thickness of 2.0–4.0 mm. The sheath material is B1 grade low-smoke halogen-free material, with the addition of special termite repellent and additives, which can prevent the growth of mold and aquatic parasites for a long time, effectively prevent termite gnawing, and has excellent anti-corrosion and corrosion-resistant properties, thus providing protection.

[0062] The advantages of this invention are as follows:

[0063] 1. The product simultaneously possesses information control, network interconnection, and power transmission functions. Adopting a composite structure, it combines different functional products, reducing cable laying costs and simultaneously enabling upstream connections for fiber-to-the-home power supply, as well as power line monitoring and early warning functions, improving fault response speed and reducing line maintenance costs.

[0064] 2. Excellent fire resistance: Under rated working voltage, the flame temperature of the cable is not lower than 750℃, and the fuse does not break within 90 minutes of fire exposure.

[0065] 3. Economic efficiency: A reasonable structure and appropriate fire-resistant materials are selected to meet the fire resistance requirements of the cables, while also taking into account material selection, structural dimensions, and electrical performance, thereby reducing costs.

[0066] 4. Environmentally friendly: Free of heavy metals, non-toxic, odorless, and has no impact on human health or the environment; ant-proof, rodent-proof, waterproof, and oil-resistant.

[0067] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.

Claims

1. A composite cable for use in integrated utility tunnels, characterized in that: Composite cables consist of optical fiber units, communication control cable units, and power cable units. Water-blocking filler ropes are used to fill the gaps between the optical fiber units, communication control cable units, and power cable units. After the optical fiber units, communication control cable units, and power cable units are twisted together, they are wrapped with an external comprehensive protective layer to form a cable. A power cable unit consists of several power conductor cores, which are wrapped together by an insulating tape. Water-blocking ropes are filled between adjacent power conductor cores. The water-blocking ropes are mixed with refractory aggregate particles, and a sheath is extruded onto the surface of the insulating tape. The optical cable unit consists of a non-metallic reinforcing member located in the center and several optical fiber bundles arranged around the non-metallic reinforcing member. Each optical fiber bundle contains 2-12 optical fibers. The middle part of the non-metallic reinforcing member is an elastic bending part, and several reinforcing support parts are embedded around the elastic bending part. The communication control cable unit includes several communication conductor cores. Each communication conductor core includes two single cores. The two single cores are wrapped with polyester tape and copper-plastic composite tape to form the communication conductor cores. Water-blocking yarn is filled between the single cores. Several communication conductor cores are wrapped with water-blocking tape to form a cable. Water-blocking yarn is filled between the communication conductor cores.

2. The composite cable for integrated utility tunnels according to claim 1, characterized in that: Water-blocking filler ropes are used to fill the gaps between the optical cable unit, the communication control cable unit, and the power cable unit. The comprehensive protective layer consists of, from the inside out, the main cable water-blocking strip, the fire-resistant layer, the corrugated metal sheath, and the outer sheath.

3. The composite cable for integrated utility tunnels according to claim 1, characterized in that: The non-metallic reinforcing member is cylindrical, with the elastic bending part in the middle made of rubber, polyurethane or nylon. Four reinforcing support parts are evenly embedded around the elastic bending part, and the reinforcing support parts are made of fiber-reinforced composite plastic.

4. The composite cable for integrated utility tunnels according to claim 1, characterized in that: The volume ratio of the reinforced support section to the flexible bending section is 1:2-5.

5. The composite cable for integrated utility tunnels according to claim 1, characterized in that: The power cable unit includes four power conductor cores, which are made of copper conductors wrapped with mica tape and a ceramicized polyolefin fireproof insulation layer with a thickness of 1.0-2.5mm. The water-blocking rope is made of inorganic non-combustible expanded fiberglass rope, the insulation tape is made of halogen-free high flame-retardant tape with a thickness of 0.15-0.25mm, and the sheath is made of low-smoke halogen-free sheath material extruded with a thickness of 1.2-1.8mm. The volume ratio of refractory aggregate particles to water-blocking rope is 1:8-16.

6. The composite cable for integrated utility tunnels according to claim 1, characterized in that: The refractory aggregate particles are made of alumina hollow spheres with a diameter of 0.2-5mm and zirconia hollow spheres with a diameter of 1-0.15mm, with a mass ratio of alumina hollow spheres to zirconia hollow spheres of 1:0.8-1.

5.

7. The composite cable for integrated utility tunnels according to claim 1, characterized in that: The optical cable unit has 5 optical fiber bundles. The 5 optical fiber bundles are bundled into a cable by wrapping the optical cable unit with water-blocking tape. Water-blocking yarn is filled between the 5 optical fiber bundles. The water-blocking tape of the optical cable unit is wrapped with aramid yarn. The aramid yarn is then extruded with an anti-tracking sheath material with a thickness of 1-1.5mm.

8. The composite cable for integrated utility tunnels according to claim 1, characterized in that: In the communication control cable unit, each single core is made of oxygen-free copper wire extruded with a ceramicized polyolefin fire-retardant insulation layer, the thickness of which is 0.8-1.5mm. Two single cores are wrapped with double-layer polyester tape to form a cable. The copper-plastic composite tape includes a copper tape layer and a plastic layer, with the copper tape layer placed close to the core. Three communication conductor cores are wrapped with water-blocking tape to form the communication control cable unit. The water-blocking tape is extruded with a low-smoke halogen-free sheath material, the thickness of which is 1.0-1.5mm.

9. The method for preparing composite cables for integrated utility tunnels according to claim 1, characterized in that: The preparation method includes the following steps: a) Manufacturing a power cable unit, which includes four power conductor cores. The power conductor cores are made of copper conductors wrapped with mica tape and a ceramicized polyolefin fireproof insulation layer. The thickness of the ceramicized polyolefin fireproof insulation layer is 1.0-2.5mm. The water-blocking rope is made of inorganic non-combustible expanded glass fiber rope, and the insulation tape is made of halogen-free high flame-retardant wrapping tape with a thickness of 0.15-0.25mm. The sheath is made of low-smoke halogen-free sheath material extruded with a thickness of 1.2-1.8mm; b) Manufacturing an optical cable unit, which includes five optical fiber bundles and non-metallic reinforcing members. The five optical fiber bundles are cabled by wrapping water-blocking tape. Water-blocking yarn is filled between the five optical fiber bundles. Aramid yarn is wrapped around the water-blocking tape, and an anti-tracking sheath material is extruded over the aramid yarn with a thickness of 1-1.5mm; c) Manufacturing a communication control cable unit, in which a single core is made of oxygen-free copper wire extruded with ceramicized polyolefin fireproof insulation layer. Made of olefin fire-retardant insulation layer, the ceramicized polyolefin fire-retardant insulation layer has a thickness of 0.8-1.5mm. Two single cores are wrapped with double-layer polyester tape to form a cable. The copper-plastic composite tape includes a copper tape layer and a plastic layer, with the copper tape layer placed close to the core. Three communication conductor cores are wrapped with water-blocking tape to form a communication control cable unit. The water-blocking tape is extruded with a low-smoke halogen-free sheath material with a sheath thickness of 1.0-1.5mm. d. Power cable units are considered as one core, and optical cable units are considered as one core. The control cable consists of three cores twisted clockwise to the right. The gaps between the three cores are filled with water-blocking rope and then tightly wrapped with water-blocking tape with a thickness of 0.2mm. The surface of the water-blocking tape is extruded with a ceramicized polyolefin fire-resistant insulation layer as a fire-resistant layer with a thickness of 1.5-3.0mm. A corrugated metal sheath is wrapped around the fire-resistant layer, and a low-smoke halogen-free sheath material is extruded over the corrugated metal sheath as an outer sheath with a thickness of 1.5-2.5mm.

10. The method for preparing composite cables for integrated utility tunnels according to claim 1, characterized in that: The non-metallic reinforcing member is cylindrical, with the elastic bending part in the middle made of rubber, polyurethane or nylon. Four reinforcing support parts are evenly embedded around the elastic bending part, and the reinforcing support parts are made of fiber-reinforced composite plastic. The volume ratio of the reinforcing support parts to the elastic bending part is 1:2-5.

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