WO2006005426A1 - Fil electrique et constructions de cables resistants au feu - Google Patents

Fil electrique et constructions de cables resistants au feu Download PDF

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Publication number
WO2006005426A1
WO2006005426A1 PCT/EP2005/006825 EP2005006825W WO2006005426A1 WO 2006005426 A1 WO2006005426 A1 WO 2006005426A1 EP 2005006825 W EP2005006825 W EP 2005006825W WO 2006005426 A1 WO2006005426 A1 WO 2006005426A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
fire
mica
mica tape
insulated wire
Prior art date
Application number
PCT/EP2005/006825
Other languages
English (en)
Inventor
Philip James Hammond
David Barclay Tombs
John Wadeley
Original Assignee
Tyco Electronics Uk Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tyco Electronics Uk Ltd. filed Critical Tyco Electronics Uk Ltd.
Publication of WO2006005426A1 publication Critical patent/WO2006005426A1/fr

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/443—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from vinylhalogenides or other halogenoethylenic compounds
    • H01B3/445—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from vinylhalogenides or other halogenoethylenic compounds from vinylfluorides or other fluoroethylenic compounds
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
    • H01B3/04—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances mica
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame

Definitions

  • This invention relates to fire-resistant wires capable of maintaining electrical circuit integrity when the wires, or cables containing them, are exposed to fire.
  • These wires are designed for, but not limited to, use in the aerospace industry, where small diameter, lightweight and high performance are important requirements for wire harnesses.
  • Fire-resistant wires typically comprise a conductor wrapped with inorganic material in conjunction with one or more polymer layers.
  • inorganic material provides electrical insulation around the conductor once the usual layers of organic polymer insulation have been melted or burnt away.
  • mica tapes are generally preferred. This is due to this mineral's excellent thermal and dielectric properties which provide good fire resistance and high insulation values. Mica itself is also very stable to a wide range of chemicals, including those which promote hydrolysis.
  • fire resistance is often achieved by use of several layers of inflammable inorganic materials such as glass which makes the cables large and heavy whereas light weight and small size are achieved by thin layers of polymeric insulation. Large, heavy cables are not well suited for aerospace applications.
  • the present invention provides a unique wire construction capable of achieving a superior balance of characteristics such as small size, light weight, good fire-resistance, heat stability, ease of stripping, cut-through resistance, abrasion strength and solvent resistance. /Importantly, the construction provides these advantages without requiring a thick and/or heavy layer of insulation and can be readily manufactured using industry- standard wrapping and extrusion processes.
  • constructions offering a desirable combination of the required attributes can be made by first wrapping a conductor with mica tape, preferably with two layers of mica tape, then wrapping a layer of polytetrafluoroethylene (PTFE) tape over the mica layer(s), sintering the PTFE layer, and finally extruding and crosslinking (preferably by electron beam irradiation) a thin layer of poly(ethylene-co-tetrafluoroethylene) (ETFE) over the PTFE layer.
  • PTFE polytetrafluoroethylene
  • the sintered PTFE intermediate layer (a) advantageously reduces or eliminates cracking and disintegration of the relatively brittle mica, which tends to occur when the ETFE outer layer is extruded directly onto the mica layer(s); and (b) unexpectedly facilitates stripping of the insulation from the conductor when the insulated wire is being connected to electrical equipment in use.
  • the success of this fire wire insulation structure according to the present invention is surprising, since it is well known that PTFE is degraded by the electron beam irradiation which is preferred for cross-linking the ETFE outer layer.
  • Mica paper reinforced by a backing material of woven glass or of polyethylene film is produced as tape that can be spirally wrapped onto electrical conductors to give a degree of fire resistance.
  • the mica wrapped conductor is then coated with a conventional polymer to impart the required electrical and mechanical properties. In a fire, the polymer is destroyed but the electrical integrity of the cable is maintained by the mica layer and the insulating char from the polymer. It is generally understood that the more mica the better from a fire performance point of view and tapes are available with different weights of mica (e.g. 80, 120,160g./sqm).
  • Mica tapes are applied by spiral wrapping with an overlap to maintain protection when the wrapped conductor is flexed, since the overlaps tend to open on flexing.
  • either the weight of the mica tape can be increased or two or more layers of tape can be applied.
  • the tapes become more difficult to wrap successfully on small diameter conductors which can lead to tape damage, wrinkling and a poor wrapped surface.
  • the overlapped tape also tends to suffer from breakage of some of the glass weave reinforcement on small conductors due partly to the low elongation to break of the tapes. This causes glass fibre protrusions from the wrap.
  • the quality of the mica-wrapped conductor can make subsequent extrusion processing more difficult and the final appearance and/or performance of the wire less satisfactory.
  • the current invention provides a flame resistant, thin-wall, small size, lightweight wire that can be manufactured robustly using industry standard tape wrapping, extrusion and irradiation processes.
  • Polyimides and crosslinked fluoropolymers are widely used as insulation materials for high performance wire and cable, especially airframe wiring. Wires based on fluoropolymers have important characteristics such as light weight and small diameter, good cut-through, arc-track and abrasion resistance and thermal stability, low flammability, and insensitivity to water and common solvents.
  • a dual-layer insulated conductor where the inner layer is an uncrosslinked or lightly crosslinked crystalline poly(ethylene-co-tetrafluoroethylene) and the outer layer is highly crosslinked crystalline poly(ethylene-co-tetrafluoroethylene), is described in U.S. Patent No. 5,059,483.
  • Existing thin-wall, high performance wire insulation constructions include single or multi- layer cross-linked ETFE, as used for example in "Raychem Spec 55" (trade marks) wire.
  • the polymeric composition can optionally contain suitable additives such as pigments, crosslinking agents, antioxidants, thermal stabilisers, acid acceptors and processing aids.
  • the dual fluoropolymer layer of the current invention preferably comprises a layer of PTFE covering the mica and another, separate outer layer of ETFE. Electron beam irradiation of the construction provides a crosslinked mechanically tough ETFE outer layer. The inner layer of PTFE does not crosslink. The finished construction therefore provides an outer crosslinked fluoropolymer layer and an inner uncrosslinked fluoropolymer layer.
  • This type of dual layer construction is described in US 5059483 and can deliver increased resistance to cut through.
  • the presence of an uncrosslinked layer between the mica and the crosslinked outer jacket may improve of stripping the mica-coated conductor.
  • This invention is related to an insulated electrical conductor comprising an elongate electrical conductor; an electrical insulation surrounding the conductor, said insulation comprising (a) an inner, electrically insulating layer that surrounds and is in direct physical contact with the conductor, the inner layer comprising a wrapped, coated mica tape layer as hereinafter described, (b) an intermediate tape-wrapped polymeric, electrically insulating layer that surrounds and is in direct physical contact with the inner micaceous layer, the intermediate layer comprising a wrapped polymer layer, preferably PTFE and (c) an outer, electrically insulating, extruded polymeric layer that surrounds and is in direct physical contact with the intermediate polymer layer, the outer layer comprising a fluoropolymer, especially a crosslinked fluoropolymer, more especially crosslinked ETFE. Therefore one aspect of the present invention provides an insulated electrical conductor comprising:
  • electrical insulation surrounding the conductor comprising (i) a mica tape inner layer that surrounds the conductor, said mica layer preferably comprising two wraps of mica tape.
  • the first tape layer is applied with an overlap and the opposite lay direction to the strand lay, and the second tape layer applied with an overlap and the opposite lay direction to the first,
  • a PTFE layer that surrounds the mica said PTFE preferably comprising a single wrap tape applied with an overlap and in the opposite direction to the second layer of mica
  • an extruded polymeric outer electrically insulating layer preferably comprising poly(ethylene-co-tetrafluoroethylene) (ETFE).
  • an electrical cable is provided with a primary insulation of micaceous material, a secondary insulation of a fluoropolymer and a third layer of a fluoropolymer.
  • the cable itself may comprise one or more electrical conductors formed of any suitable metal, preferably copper or aluminum.
  • the cable comprises one or more twisted electrical conductors or strands.
  • the cable may be in any suitable size, such as 8 to 20 American Wire Gauge (AWG), preferably 14 to 26 AWG.
  • AWG American Wire Gauge
  • the individual conductors may be individually provided with both primary, secondary and tertiary insulation layers before being formed into a composite cable or the individual conductors may be combined before or after wrapping with the primary insulation and prior to applying the secondary layer thereon.
  • the primary layer is composed of a micaceous material.
  • this layer is in the form of a mica paper tape and is wrapped about the bare cable by conventional cable taping equipment or by direct feed into extrusion heads.
  • the mica tape may, for example, have a thickness of about 12.7 ⁇ m (0.5 mils) to about 1.27 mm (50 mils), more preferably about 25.4 ⁇ m (1 mil) to about 101.6 ⁇ m (4 mils).
  • the fluoropolymer secondary insulation may be applied to the covered conductor by any suitable manner including tape wrapping.
  • Especially preferred fluoropolymers include tetrafluoroethylene homopolymers (PTFE) and copolymers with hexafluoropropene, propylene or perfluorovinylpropyl ether, chlorotrifluoroethylene homopolymers.
  • the tape width and thickness will be selected by those skilled in the art according to the conductor size and the degree of overlap required. Tapes can be approximately 5 mm - 25 mm, more preferably 10-20 mm, wide and between about 10 to 1000 ⁇ m, more preferably about 25 to about 100 ⁇ m, thick.
  • the fluoropolymer wrapped wire is preferably sintered at high temperature, prefereably 350-450 0 C, to consolidate the insulation layer and reduce its thickness.
  • the tertiary insulation layer may be applied to the covered conductor by any suitable manner including extrusion coating, powder coating and the like.
  • the extrusion of the fluoropolymer onto the secondary insulation is preferred since high rates of production can be obtained.
  • Preferred fluoropolymers are copolymers of ethylene and tetrafluoroethylene (ETFE). Such copolymers may also contain minor amounts (e.g., up to about 15 mol %) of other comonomers; for example, a terpolymer of ethylene, chlorotrifluoroethylene and hexafluoroisobutylene may be used.
  • fluoropolymers that may be employed include tetrafluoroethylene homopolymers and copolymers with hexafluoropropene, propylene or perfluorovinylpropyl ether, chlorotrifluoroethylene homopolymers and copolymers with various alkenes, vinylidene fluoride homopolymers and copolymers with hexafluoroisobutylene, and the like.
  • the fluoropolymer layer may also include conventional additives, such as stabilizers, fillers, crosslinking agents, pigments and the like.
  • the thickness of the fluoropolymer layer may be in the range of about 127 ⁇ m (5 mils) to 2.54 mm (100 mils) or more, preferably about 254 ⁇ m (10 mils) to 508 ⁇ m (20 mils).
  • the product is preferably crosslinked by electron beam irradiation to further enhance the properties of the insulation.
  • Wires of the aforementioned construction may be employed either singularly, in bundles or in cable constructions employing additional components such as fillers, braids, tape wraps and outer jackets.
  • Nickel coated copper strand conductor 22AWG-19/34-NC
  • the first tape layer was applied at 30% overlap and the opposite lay direction to the strand lay, and the second tape layer applied at 20% overlap and the opposite lay direction to the first.
  • Over the mica was wrapped a layer of PTFE.
  • This tape was Plastomer RCL4 613A white 15/32" (11.9mm) wide with a thickness of 51 ⁇ m (2 mils). This was applied at 64% overlap and opposite direction to the second layer of mica.
  • the PTFE was then sintered at 380 0 C. This product was then extrusion coated with a thin layer, approximately 0.2 mm, of Spec TM 55, a modified ETFE insulation.
  • the finished wire was crosslinked using electron beam irradiation.
  • Nickel coated copper strand conductor (16AWG-19/29-NC) was wrapped with two layers of Cogebi 80P34A mica/glass tape 6mm wide. The first tape layer was applied at 30% overlap and the opposite lay direction to the strand lay, and the second tape layer applied at 20% overlap and the opposite lay direction to the first. Over the mica was wrapped a layer of PTFE. This tape was Plastomer RCL4 613A white 11/16" (17.5mm) wide with a thickness of 51 ⁇ m (2 mils). This was applied at 64% overlap and opposite direction to the second layer of mica. The PTFE was then sintered at 380 0 C. This product was then extrusion coated with a thin layer, approximately 0.2mm, of Spec TM 55, a modified ETFE insulation. The finished wire was crosslinked using electron beam irradiation.
  • the approximate weights per metre of 9A, 10A and 11A were 210, 323 and 41 grams respectively.
  • a metallic wire conductor 1 which may be of various solid or stranded constructions as known per se, is enclosed by two layers 2, 3 of mica tape of wire-wrapping structure known per se applied by wire- wrapping equipment and techniques generally known per se.

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  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Insulated Conductors (AREA)
  • Organic Insulating Materials (AREA)

Abstract

L'invention concerne un fil électrique isolé résistant au feu comprenant un conducteur enroulé dans un ruban de mica, une couche de poly(tétrafluoroéthylène) (PTFE) fritté recouvrant la ou les couches de mica, ainsi qu'une couche réticulée de poly(copolymère éthylène/tétrafluoroéthylène) (ETFE) recouvrant la couche de PTFE.
PCT/EP2005/006825 2004-07-09 2005-06-23 Fil electrique et constructions de cables resistants au feu WO2006005426A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0415389A GB0415389D0 (en) 2004-07-09 2004-07-09 Fire-resistant wire and cable constructions
GB0415389.6 2004-07-09

Publications (1)

Publication Number Publication Date
WO2006005426A1 true WO2006005426A1 (fr) 2006-01-19

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ID=32865701

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Application Number Title Priority Date Filing Date
PCT/EP2005/006825 WO2006005426A1 (fr) 2004-07-09 2005-06-23 Fil electrique et constructions de cables resistants au feu

Country Status (2)

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GB (1) GB0415389D0 (fr)
WO (1) WO2006005426A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009138971A2 (fr) * 2008-05-14 2009-11-19 Nexans Fil et câble électriques à revêtement en ptfe dur
CN103413598A (zh) * 2013-08-19 2013-11-27 宝胜科技创新股份有限公司 航空航天用耐火电缆及其生产工艺
EP2760030A1 (fr) * 2013-01-28 2014-07-30 Nexans Cable d'énergie et/ou de télécommunication comportant au moins une couche éléctriquement isolante
CN105632593A (zh) * 2015-12-30 2016-06-01 合肥星辰电线电缆股份有限公司 一种铜芯聚氯乙烯复合绝缘软电缆
WO2016128785A1 (fr) * 2015-02-10 2016-08-18 Prysmian S.P.A. Câble résistant au feu
WO2017130016A1 (fr) * 2016-01-26 2017-08-03 Prysmian S.P.A. Système de câble résistant au feu
CN112908538A (zh) * 2021-02-04 2021-06-04 湖南至和电缆科技有限公司 一种耐高温防火电缆及其制备方法
CN113205905A (zh) * 2021-04-28 2021-08-03 成都国恒空间技术工程有限公司 一种柔性结构航天航空1394b数据总线电缆
CN113421705A (zh) * 2021-06-21 2021-09-21 中航光电科技股份有限公司 一种耐火电缆组件及其制作方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4079191A (en) * 1975-07-07 1978-03-14 Allied Chemical Corporation Electrical wire for use in nuclear generating stations
US5059483A (en) * 1985-10-11 1991-10-22 Raychem Corporation An electrical conductor insulated with meit-processed, cross-linked fluorocarbon polymers
WO2000074075A1 (fr) * 1999-06-02 2000-12-07 Tyco Electronics Corporation Conducteur electrique isole
EP1211696A1 (fr) * 2000-12-01 2002-06-05 Compagnie Royale Asturienne Des Mines, Societe Anonyme Conducteur électrique isolé

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4079191A (en) * 1975-07-07 1978-03-14 Allied Chemical Corporation Electrical wire for use in nuclear generating stations
US5059483A (en) * 1985-10-11 1991-10-22 Raychem Corporation An electrical conductor insulated with meit-processed, cross-linked fluorocarbon polymers
WO2000074075A1 (fr) * 1999-06-02 2000-12-07 Tyco Electronics Corporation Conducteur electrique isole
EP1211696A1 (fr) * 2000-12-01 2002-06-05 Compagnie Royale Asturienne Des Mines, Societe Anonyme Conducteur électrique isolé

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009138971A3 (fr) * 2008-05-14 2010-02-25 Nexans Fil et câble électriques à revêtement en ptfe dur
US8884163B2 (en) 2008-05-14 2014-11-11 Nexans Skin cured PTFE wire and cable
WO2009138971A2 (fr) * 2008-05-14 2009-11-19 Nexans Fil et câble électriques à revêtement en ptfe dur
EP2760030A1 (fr) * 2013-01-28 2014-07-30 Nexans Cable d'énergie et/ou de télécommunication comportant au moins une couche éléctriquement isolante
FR3001574A1 (fr) * 2013-01-28 2014-08-01 Nexans Cable d'energie et/ou de telecommunication comportant au moins une couche electriquement isolante
CN103413598A (zh) * 2013-08-19 2013-11-27 宝胜科技创新股份有限公司 航空航天用耐火电缆及其生产工艺
AU2015382306B2 (en) * 2015-02-10 2021-01-28 Prysmian S.P.A. Fire resistant cable
WO2016128785A1 (fr) * 2015-02-10 2016-08-18 Prysmian S.P.A. Câble résistant au feu
US10453588B2 (en) 2015-02-10 2019-10-22 Prysmian S.P.A. Fire resistant cable
CN105632593A (zh) * 2015-12-30 2016-06-01 合肥星辰电线电缆股份有限公司 一种铜芯聚氯乙烯复合绝缘软电缆
WO2017130016A1 (fr) * 2016-01-26 2017-08-03 Prysmian S.P.A. Système de câble résistant au feu
AU2016389384B2 (en) * 2016-01-26 2021-03-04 Prysmian S.P.A. Fire resistive cable system
US11276511B2 (en) 2016-01-26 2022-03-15 Prysmian S.P.A. Fire resistive cable system
CN112908538A (zh) * 2021-02-04 2021-06-04 湖南至和电缆科技有限公司 一种耐高温防火电缆及其制备方法
CN113205905A (zh) * 2021-04-28 2021-08-03 成都国恒空间技术工程有限公司 一种柔性结构航天航空1394b数据总线电缆
CN113421705A (zh) * 2021-06-21 2021-09-21 中航光电科技股份有限公司 一种耐火电缆组件及其制作方法

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