Halogen-Free Data Cable with Intumescent Tape

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Solution Overview

Problem

Conventional data communication cables have poor smoke and flame-retardant properties, and the use of halogenated or fluorinated materials to address this issue leads to the release of toxins and increased stiffness, dielectric constant, and electrical dissipative properties, necessitating a halogen-free and fluoropolymer-free solution that maintains electrical and mechanical properties while exhibiting excellent flame spread and emission characteristics.

Innovation Solution

A halogen-free data cable design featuring insulated conductors twisted into pairs with an intumescent tape and a jacket made from a thermoplastic polymer with a glass transition temperature of about 160° C or higher, which passes the UL 910 Steiner Tunnel Test, using materials such as polyethersulfone, polyetherimide, and polyphenylsulfone, and intumescent tapes with nitrogen or phosphorus flame retardants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated or fluorinated materials are used to improve flame-retardant properties, then flame spread resistance is improved, but toxic substances are released and cable stiffness increases

Engineering Contradiction:

Improveflame-retardant propertiesVSAvoidtoxin release

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical composition parameters by using halogen-free and fluoropolymer-free materials, specifically employing conventional polymers like polyethylene and polypropylene combined with intumescent flame retardants. This parameter change eliminates toxic halogen and fluorine compounds while maintaining flame-retardant effectiveness through alternative chemical mechanisms.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite cable structure combining conventional polymer insulation materials with intumescent tape layers containing flame retardant chemicals. This composite approach integrates the structural integrity of standard polymers with the protective flame-retardant properties of the intumescent layer, achieving fire resistance without toxic emissions.

Inventive Principle:

Principle #40Composite materials

2Reliability

If halogenated or fluorinated materials are used to improve flame-retardant properties, then flame spread resistance is improved, but cable flexibility deteriorates

Engineering Contradiction:

Improveflame-retardant propertiesVSAvoidcable flexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent modifies the material composition by eliminating halogenated and fluorinated stiffening agents, using instead flexible conventional polymers combined with intumescent flame retardants. This parameter change maintains cable flexibility while achieving the required flame-retardant properties through the intumescent mechanism rather than chemical stiffening.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If halogenated or fluorinated materials are used to improve flame-retardant properties, then flame spread resistance is improved, but dielectric constant increases

Engineering Contradiction:

Improveflame-retardant propertiesVSAvoidsignal quality

Core Design Contradiction:

ReliabilityVSLoss of information

Solution Approach 1:

The patent changes the dielectric material composition by using conventional polymers with lower dielectric constants instead of halogenated or fluorinated materials. The intumescent flame retardant system provides fire protection without the high dielectric constant associated with halogen-containing materials, thereby preserving signal quality and reducing electrical losses.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If halogenated or fluorinated materials are used to improve flame-retardant properties, then flame spread resistance is improved, but electrical dissipative properties worsen

Engineering Contradiction:

Improveflame-retardant propertiesVSAvoidelectrical dissipative properties

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent modifies the electrical material properties by eliminating halogenated and fluorinated compounds that increase electrical dissipative losses. The combination of conventional polymers with intumescent flame retardants achieves fire resistance while maintaining low dielectric loss and minimal electrical energy dissipation, preserving signal integrity.

Inventive Principle:

Principle #35Parameter changes

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 effectively maintains optimal electrical and mechanical properties while meeting stringent flame spread and smoke producing requirements, ensuring safety and performance in plenum applications without releasing toxic substances.

Implementation Method 1

at least one intumescent tape surrounding at least one of the pairs of insulated conductors

Methodology Applied

Scientific EffectIntumescent expansion: Intumescent Materials

Implementation Method 2

The jacket is produced from a first thermoplastic polymer having a glass transition temperature at about 160° C. or higher

Methodology Applied

Scientific EffectGlass transition:

Data Source

PatentUS9589703B2Data cables having an intumescent tape

Publication Date: 2017.03.07 GENERAL CABLE TECH CORP

AI summary

A data cable can include a plurality of insulated conductors twisted into pairs, an intumescent tape surrounding one or more of the insulated conductors, and a jacket. Each of the plurality of insulated conductors includes a conductor and an insulation layer. Data cables being fluoropolymer-free or halogen free are also described herein.