Vanadium Phosphate Glass Composite for Cable Jacket Flame Retardancy

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Solution Overview

Problem

Current flame retardants for polyolefin materials, such as those used in plenum cables, fail to meet rigorous testing standards due to high decomposition temperatures and environmental hazards associated with halogenated compounds, while existing non-halogenated alternatives are costly and ineffective in achieving self-extinguishing properties.

Innovation Solution

A composite material comprising at least 40 weight percent polyolefin and 5 to 60 weight percent vanadium phosphate glass, made by heating a mixture of vanadium oxide, phosphorus oxide, and antimony oxide, then quenching and milling to form glass particles, which are compounded with a polymeric material to enhance flame retardancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If halogenated flame retardants are used, then flame retardancy is improved, but environmental harm and equipment corrosion worsen

Engineering Contradiction:

Improveflame retardancyVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention changes the chemical composition parameters by using vanadium phosphate glass instead of halogenated compounds, achieving flame retardancy through a different chemical mechanism that does not produce harmful gases

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potentially harmful interaction between flame retardant and polymer into a beneficial synergistic effect, where the vanadium phosphate glass enhances flame retardancy while the polyolefin provides structural integrity, and together they achieve self-extinguishing properties

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If PVC or Teflon based materials are used, then flame retardancy is improved, but cost worsens

Engineering Contradiction:

Improveflame retardancyVSAvoidcost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention uses cost-effective vanadium phosphate glass particles combined with inexpensive polyolefin materials to create a flame retardant composition that meets performance requirements at lower cost than premium materials like PVC or Teflon

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention creates a composite material system combining inorganic vanadium phosphate glass particles with organic polyolefin matrix, achieving flame retardancy through the synergistic interaction of different material components

Inventive Principle:

Principle #40Composite materials

3Reliability

If magnesium dihydroxide or aluminum trihydrate are used, then flame retardancy is improved, but processing temperature limitation worsens

Engineering Contradiction:

Improveflame retardancyVSAvoidprocessing temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The invention changes the thermal stability parameter by selecting vanadium phosphate glass with a decomposition temperature above 1000°C, which is significantly higher than the processing temperatures of polyolefins, thus eliminating the processing temperature limitation

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If polyolefin materials are used, then cost is improved, but flame retardancy worsens

Engineering Contradiction:

ImprovecostVSAvoidflame retardancy

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The invention introduces vanadium phosphate glass particles as an intermediary flame retardant agent that mediates between the polyolefin matrix and the fire environment, absorbing heat and forming a protective barrier that prevents combustion

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The vanadium phosphate glass contains metal oxides that can catalyze flame retardant reactions and promote the formation of protective char layers, accelerating the development of self-extinguishing properties

Inventive Principle:

Principle #38Strong oxidants (Accelerated oxidation)

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 vanadium phosphate glass composite achieves a V-0 rating in UL-94 testing and reduces heat release rate, enabling self-extinguishing properties and minimizing environmental harm, while being cost-effective for use in fiber optic cable jackets.

Implementation Method 1

The vanadium phosphate glass composite achieves a V-0 rating in UL-94 testing and reduces heat release rate, enabling self-extinguishing properties

Methodology Applied

Scientific EffectHeat release rate reduction:

Implementation Method 2

heating the mixture to a temperature of from about 850° C. to about 1000° C. that is sufficient to melt the mixture

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

quenching the melt to form a glass

Methodology Applied

Scientific EffectQuenching:

Data Source

PatentUS8598268B2Flame retardant cable jacket materials including vanadium phosphate

Publication Date: 2013.12.03 CCS TECHNOLOGY INC

AI summary

A material is disclosed having improved flame retardant properties and is particularly applicable as a jacket for a fiber optic cable. The material is comprised of a polymeric base compounded with a vanadium phosphate glass composition. The polymeric base may be a flame retardant polyethylene and the vanadium phosphate glass composition contains vanadium oxide, phosphorus oxide and antimony oxide. The material achieves a V-0 rating when tested per Underwriters Laboratory test UL-94 and has a heat release rate value consistent with a self extinguishing material when combusted.