Magnesium Oxide Dielectric Layer for Halogen-Free Flame-Retardant Cables
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Solution Overview
Problem
Designing flame-retardant electrical cables that maintain required electrical properties, such as a stable dielectric constant and low loss tangent, while being halogen-free is challenging due to the limitations of existing materials that often compromise dielectric properties.
Innovation Solution
The use of magnesium oxide as a dielectric material in a flat electrical cable, with specific deposition methods and layer configurations, to achieve the necessary dielectric and flame-retardant properties without halogens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If halogen-containing flame-retardant materials are used, then flame-retardance is improved, but halogen-free requirements are violated
Solution Approach 1:
The patent changes the chemical composition parameters of the dielectric material from conventional polymers to magnesium oxide ceramic, achieving flame-retardance without halogens. This parameter change in material composition resolves the contradiction between flame-retardance requirements and halogen-free specifications.
Solution Approach 2:
The patent uses composite material construction with multiple dielectric layers, where the magnesium oxide layer provides flame-retardance while the overall composite structure maintains electrical properties. This composite approach allows simultaneous achievement of flame-retardance and halogen-free requirements.
2Reliability
If conventional flame-retardant materials are used, then flame-retardance is improved, but dielectric properties are reduced
Solution Approach 1:
The patent changes the dielectric material from organic polymers to inorganic magnesium oxide, fundamentally altering the material parameters to achieve both flame-retardance and superior dielectric properties with Dk < 2.35 and Df < 0.0005, resolving the contradiction between flame-retardance and dielectric performance.
Solution Approach 2:
The patent employs a thin magnesium oxide dielectric layer (replacing thicker conventional dielectric materials) that provides equivalent or superior electrical performance while maintaining flame-retardance, effectively using a thinner, more efficient material solution.
3Reliability
If high flame-retardance is achieved through material composition, then flame-retardance is improved, but dielectric constant stability and loss tangent are compromised
Solution Approach 1:
The patent changes to magnesium oxide material with inherently stable dielectric properties (Dk < 2.35, Df < 0.0005) that maintain composition stability across frequencies while providing flame-retardance, resolving the contradiction between flame-retardance and dielectric constant stability.
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 magnesium oxide dielectric layer ensures a stable dielectric constant below 2.35 and low loss tangent across various frequencies, meeting both flame-retardance and halogen-free requirements effectively.
Implementation Method 1
The first dielectric layer may be a vacuum deposited layer, a vapor deposited layer, a chemically vapor deposited (CVD) layer, a plasma enhanced chemically vapor deposited (PECVD) layer, a sputtering deposited layer, a low-pressure chemically vapor deposited (LPCVD) layer, a plasma assisted chemically vapor deposited (PACVD) layer, an atomic layer deposited (ALD) layer, a thermally vapor deposited layer, an electron beam vapor deposited layer, a laser ablated vapor deposited layer, and/or a physically vapor deposited (PVD) layer.
Data Source
AI summary
A flame-retardant flat electrical cable has a magnesium oxide dielectric layer. A plurality of spaced apart substantially parallel electrical conductors generally lie in the same plane and extend along the length of the cable. A dielectric layer is disposed on the top and/or bottom sides of the cable and covers the conductors. The dielectric layer has at least 90% magnesium oxide by weight.