Flat Electrical Cable With Intumescent Edge Conductors
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Solution Overview
Problem
Existing electrical cables face challenges in balancing signal transmission properties with flame retardancy, as halogen-based flame retardants can degrade dielectric properties, and existing solutions struggle to meet both high-speed data transmission and flame resistance requirements.
Innovation Solution
A flat electrical cable design featuring conductor sets with intumescent flame retardant material in edge conductors for enhanced flame resistance and halogen-free dielectric properties, allowing for separate use of edge and middle conductors for low-speed and high-speed data transmission respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-based flame retardants are used in the dielectric material, then flame resistance is improved, but dielectric properties and signal transmission quality deteriorate
Solution Approach 1:
The cable is divided into edge conductor sets and middle conductor sets with different dielectric material compositions. Edge conductors use dielectric material with intumescent flame retardant for flame resistance, while middle conductors use dielectric material without flame retardant for optimal signal transmission. This segmentation allows each segment to be optimized for its specific function.
Solution Approach 2:
Different parts of the cable have different dielectric material properties tailored to their specific requirements. Edge conductors have flame-retardant dielectric material for safety, while middle conductors have high-performance dielectric material for signal integrity. This local differentiation resolves the contradiction by applying the right material properties where needed.
2Reliability
If flame retardant material is added to dielectric material, then flame resistance is improved, but dielectric properties deteriorate
Solution Approach 1:
The dielectric material is segmented into two types: flame-retardant dielectric material for edge conductors and non-flame-retardant dielectric material for middle conductors. This segmentation allows manufacturing processes to be optimized separately for each material type, ensuring that flame retardancy requirements are met without compromising the dielectric properties of signal-critical conductors.
Solution Approach 2:
The cable employs composite material construction with different dielectric materials in different locations. Edge conductors use composite dielectric material containing intumescent flame retardant, while middle conductors use pure dielectric material without flame retardant additives, maintaining optimal electrical properties.
3Reliability
If all conductors use flame-retardant dielectric material, then flame resistance is improved, but signal transmission performance for high-speed data deteriorates
Solution Approach 1:
The cable structure is segmented into flame-retardant edge conductors and high-speed middle conductors. This allows middle conductors to be dedicated to high-speed data transmission without flame retardant interference, while edge conductors provide flame protection and can handle lower-speed signals.
Solution Approach 2:
High dielectric performance is locally applied to middle conductors where high-speed signal transmission is critical, while flame retardancy is locally applied to edge conductors where signal speed requirements are lower. This localized optimization resolves the speed-performance contradiction.
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 cable achieves effective flame resistance while maintaining suitable dielectric properties for high-speed data transmission, conforming to industry standards for halogen-free materials and flame resistance.
Implementation Method 1
The first dielectric material of each insulated conductor of the edge, but not the middle, conductor set includes an intumescent flame retardant material
Data Source
AI summary
A flat electrical cable extends longitudinally along a length of the cable. The flat electrical cable includes a plurality of conductor sets extending along the length of the cable. Each conductor set includes one or more insulated electrical conductors. Each insulated conductor includes a central conductor surrounded by a first dielectric material. The plurality of conductor sets includes a middle conductor set disposed between two other conductor sets and an edge conductor set disposed proximal to a longitudinal edge of the cable. The first dielectric material of each insulated conductor of the edge, but not the middle, conductor set includes an intumescent flame retardant material.