Fire-Resistant Cable Insulating Layer Using Geopolymer Composite
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Solution Overview
Problem
Existing fire-resistant insulating layers in electrical and data transmission cables lack satisfactory fire resistance and mechanical properties, and previous solutions are costly and not compatible with preserving mechanical and dielectric properties.
Innovation Solution
A composite material-based fire-resistant insulating layer comprising a cementitious material (5-95% by mass) and a non-woven fibrous material with a flexible structure, along with a geopolymer cement that hardens through internal polycondensation, is used as an internal layer in cables and accessories, providing enhanced fire resistance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer-based insulating layers with fire-retardant fillers are used, then fire resistance is improved, but mechanical properties and flexibility deteriorate
Solution Approach 1:
The patent uses a composite material comprising a polymer matrix (such as polyorganosiloxane) combined with inorganic fillers (such as mica particles, glass fibers, and other fire-retardant additives) to create an insulating layer that simultaneously achieves both fire resistance and mechanical strength. The composite structure allows the polymer to provide flexibility and adhesion while the inorganic fillers provide fire resistance and structural reinforcement.
2Reliability
If multiple superimposed insulating strips with mica and glass fibers are used, then fire resistance is improved, but production cost and preparation time increase
Solution Approach 1:
The patent combines multiple fire-resistant components (mica particles, glass fibers, and other inorganic fillers) into a single integrated insulating layer formulation applied in one coating process. This eliminates the need for multiple separate application steps required by prior art methods using superimposed strips, thereby reducing preparation time and simplifying production while maintaining fire resistance.
3Reliability
If refractory tape with porous base fabric and finely divided alumina or zirconia is used, then fire resistance is improved, but flexibility and ease of handling deteriorate
Solution Approach 1:
The patent employs a flexible polymer matrix (such as polyorganosiloxane or other elastomeric polymers) as the base material for the insulating layer, which inherently provides flexibility and ease of handling. Fire resistance is then achieved by incorporating fire-retardant fillers into this flexible matrix, creating a coating that can conform to cable surfaces and withstand handling during installation while maintaining fire-resistant properties.
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 achieves good fire resistance up to 1000°C for 120 minutes while maintaining mechanical integrity, meeting various fire resistance standards and allowing for easy handling and manipulation of cables without compromising cohesion or resistance.
Implementation Method 1
Geopolymers are essentially inorganic chemical compounds or mixtures of compounds consisting of silico-oxide (-Si-O-Si-O-), silico-aluminate (-Si-O-Al-O-), ferro-silico-aluminate (-Fe-O-Si-O-AI-O-), or alumino-phosphate (-AI-O-P-O-), created by a process of geopolymerization (i.e. polycondensation).
Implementation Method 2
Hardening occurs by simple hydration of calcium aluminates and calcium silicates and the binding cement paste retains its strength and stability after hardening.
Data Source
AI summary
The invention relates to a device comprising a cable and/or a cable accessory, said cable and/or cable accessory containing at least one insulating and fire-resistant layer, as well as to a method for manufacturing a cable and/or accessory of said type.