Flat Cable with Inter-Strand Fire Resistant Insulation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional electrical cables and installation systems fail to maintain circuit integrity during fires, as the insulation melts or burns off quickly, leading to short circuits due to the close proximity of conductors and mechanical stress, which is a complex technical challenge to address with existing standards.

Innovation Solution

A flat cable design with fire-resistant insulating material between high-power current strands, and a connection device with threaded contact screws that clamp the conductors laterally to prevent short circuits, even when the insulation burns off, along with a cylindrical deflection element for maintaining cable orientation without mechanical tension.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional cables are used with standard insulation, then the cable structure is simple, but the insulation melts or burns off quickly under fire influence leading to short circuits

Engineering Contradiction:

Improvecircuit integrityVSAvoidcable structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable is divided into multiple independent current-carrying strands, each surrounded by its own fire-resistant insulating material. This segmentation ensures that if one strand fails, others remain isolated and functional, maintaining circuit integrity during fire exposure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cable employs composite construction combining fire-resistant insulating material (such as ceramic-coated strands or intumescent coatings) with conventional conductors. This composite approach provides both electrical conductivity and fire resistance, resolving the contradiction between reliability under fire and structural simplicity.

Inventive Principle:

Principle #40Composite materials

2Volume of moving object

If conductors are placed close together to reduce cable size, then the cable dimensions are reduced, but the proximity increases short circuit risk when insulation fails

Engineering Contradiction:

Improvecable cross-sectionVSAvoidshort circuit prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

Fire-resistant insulating material acts as an intermediary barrier between adjacent conductors. This intermediate layer maintains electrical isolation even when conventional insulation degrades, preventing short circuits while allowing compact conductor spacing.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Fire-resistant insulating material is applied locally at critical interfaces between conductors where short circuit risk is highest. This localized protection optimizes the balance between cable compactness and short circuit prevention.

Inventive Principle:

Principle #3Local quality

3Reliability

If mechanical stress resistance is improved through rigid support structures, then circuit integrity is maintained, but the installation complexity and device complexity increase

Engineering Contradiction:

Improvemechanical stress resistanceVSAvoidsupport structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cable design incorporates flexible fire-resistant insulation that dynamically responds to mechanical stress and thermal expansion. This dynamic property allows the cable to maintain structural integrity under stress without requiring rigid external support structures, reducing installation complexity.

Inventive Principle:

Principle #15Dynamics

4Reliability

If fire-resistant materials are used to maintain insulation during fire, then circuit integrity is improved, but the manufacturing complexity and material cost increase

Engineering Contradiction:

Improvefire resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Fire-resistant insulating material or coatings are applied during the cable manufacturing process before final assembly. This preliminary action ensures fire protection is integrated into the cable structure itself, simplifying installation and reducing the need for additional fire protection measures.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides extended circuit integrity durations with reduced technical complexity, preventing short circuits and maintaining electrical connectivity during fires by using fire-resistant materials and innovative cable and connection device designs.

Implementation Method 1

Fire resistant insulating material is arranged between the high power current strands

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The contact screws include a thread so that the conductor is laterally clamped by both threaded contact screws

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Data Source

PatentUS8822826B2Cable and installation kit for electrical installation with circuit integrity in case of fire

Publication Date: 2014.09.02 WOERTZ

AI summary

A cable providing circuit integrity in case of fire is configured as a flat cable with plural high power current strands extending parallel adjacent to one another in a plane. Fire resistant insulating material is arranged between the high power current strands. An insulating jacket envelopes the high power current strands and the fire resistant insulating material.