FIRE RESISTANT CABLE AND METHOD OF MANUFACTURE
This invention relates to a fire resistant cable and method of manufacture. In particular, this invention relates to a fire resistant cable suitable for use in critical and emergency signal paths, such as, for example, fire alarm systems or emergency lighting, and which provides sufficient resistance to the effects of fire and water.
Recently, the development of 'soft-skinned' fire resistant cables, which use various grades of polymer-based insulation inside a thin metallic or microglass sheath have become a viable alternative to more traditional 'fire survival' cables, such as MICC (Mineral Insulated Copper Coated) cables. iyilCC cables are well known in the prior art and consist of copper conductors within a copper external sheath and the void inside the sheath is filled with a mineral insulation of magnesium oxide. This type of cable is virtually indestructible with a high mechanical strength. Although MICC cables are of a high quality and robust, they are much more difficult to install than their soft-skinned counterparts. The other main disadvantage is that MICC cable is very inflexible due to its very high mechanical strength.
Whilst soft-skinned fire resistant cables cannot match MICC cables in terms of sustained fireproof performance, significant developments have been "made.ϊn recent' years "so -.that such are capable of meeting the requirements of BS 5839 Part 1 : 2002, Clause 26.2 for standard fire resisting cables; EN 50200' PH- "30; BS 6387 Categories C, W and Z: 1994; BS 7629 Part 1 : 1997; and BS ,843.4 Part 1 : 2003. BS 5839 Part 1 : 2002, Clause 26.2 has recently been further revised to define a more stringent standard for use in critical signal paths, and termed enhanced fire resisting cables. Enhanced cables must be used in unsprinklered buildings (i) greater than 30m in height,
or (ii) with four or more evacuation zones, or (iii) for example, hospitals or other buildings, where there are horizontal evacuation arrangements, or (iv) where a risk assessment identifies a possible need.
The cross section of a prior art soft-skinned fire resistant cable is shown in Figure 1 and comprises typically of annealed copper conductors 10 each within an insulating sheath 14, which generally comprises a microglass tape inner (not shown) and silicon rubber outer (not shown). Typically, an uninsulated circuit protective conductor 12 is also provided. A thin metallic tape or foil 16, which is usually copper, is then rolled around such inner conductors 10, 12, which is then enclosed within a halogen-free fire resistant protective outer sheath 18.
As shown in Figure 2, the current method for covering the inner conductors 10, 12 with the metallic tape 16 is to roll the metallic tape 16 around the inner conductors 10, 12 and a small overlap of around 1mm is bonded to itself and to the protective outer sheath 18. However, the problem associated with this approach is that such design often allows the metallic tape 16 to come apart and bare the inner conductors 10, 12 during a fire condition. The fact that such cables are able to meet the requirements of the relevant standards lies in the use of the two-part insulating sheath 14 having a microglass tape inner and silicon rubber outer. In particular, if the metallic tape 16 comes apart for the reasons described above, the integrity of the inner circuit conductors 10 is only maintained by the inner microglass tape wound around each inner conductor 10. Disadvantageously, the use of such a two-part insulating sheath 14 lies in the cost and manufacture of the cable.
Previous examples of electrical cabling arrangements for use in chemically corrosive environments have been proposed and utilise a metallic sheath which encloses the inner conductors; the edges of the metallic sheath being externally folded and sealed with a sealant for maintaining the moisture and gas integrity of the cable, as disclosed in US 5,451 ,718. For the reasons
described above, the power cable disclosed in US 5,451 ,718 would not be able to meet the relevant standards for fire resistant cables.
It is the object of the present invention to provide a fire resistant cable that is pliable, quick and easy to install, without the need for specialised tools.
In a fire condition, the metallic tape encasing the inner conductors stays intact, such that the inner conductors are not exposed to fire and water, and which may prevent premature failure of the cable. The configuration of the metallic tape ensures that the inner conductors are not exposed to fire and water, and, as such, a standard unitary polymer-based insulation can be used for insulating the inner conductor. It is a further object of the present invention to provide a fire resistant cable that has a higher mechanical strength and is more durable than conventional soft-skinned fire resistant cables.
According to the present invention there is provided a fire resistant cable, comprising: at least one insulated electrical conductor contained within a fire resistant protective outer sheath; and a metallic tape situated between said at least one insulated electrical conductor and said protective outer sheath, said metallic tape being folded and rolled inwardly at its edge to facilitate increased reliability in a fire condition.
In a preferred embodiment, said at least one insulated electrical conductor comprises an annealed copper conductor having an insulating sheath. Preferably, said insulating sheath comprises a polymer-based insulator having a unitary cross section. Further, preferably, said insulating sheath comprises silicon rubber. In use, a circuit protective conductor is also provided which is uninsulated, and is in direct contact with said metallic tape.
Preferably, in use, said metallic tape may be formed from copper or aluminium or any other suitable metallic foil. Said metallic tape completely
encompasses said at least one insulated electrical conductor and may be double-folded or triple-folded at is edge against itself to prevent the metallic tape opening in a fire condition.
Further preferably, said fire resistant protective outer sheath may be provided using any suitable halogen-free protective sheath.
Also according to the present invention there is provided a method of manufacturing a fire resistant cable comprising at least one insulated electrical conductor, comprising the steps of: rolling a metallic tape having first and second longitudinal edges around said at least one insulated electrical conductor into an overlapped abutting configuration; folding said first and second longitudinal edges of said metallic tape back on itself to secure said at least one insulated electrical conductor; rolling said first and second longitudinal edges of said metallic tape inwardly through an angle of at least 180°; and bonding a fire resistant protective outer sheath around said metallic tape.
Preferably, the step of rolling said first and second longitudinal edges of said metallic tape inwardly through an angle of at least 180° may be repeated such that the total angle of rotation is around 360° or 540° or more.
It is believed that a fire resistant cable and method of manufacture in accordance with the present invention at least addresses the problems outlined above. In particular, the advantages of the present invention are that a fire resistant cable is provided that is pliable, quick and easy to install, without the need for specialised tools. Advantageously, in a fire condition, the metallic tape encasing the inner conductors stays intact, such that the inner conductors are not exposed to fire and water, and which may prevent premature failure of the cable. The configuration of the metallic tape ensures that the inner conductors are not exposed to fire and water, and, as such, a
standard unitary polymer-based insulation can be used for insulating the inner conductor. It is a further advantage of the present invention that a fire resistant cable is provided that has a higher mechanical strength and is more durable than conventional soft-skinned fire resistant cables.
It will be obvious to those skilled in the art that variations of the present invention are possible and it is intended that the present invention may be used other than as specifically described herein.
A specific and non-limiting embodiment of the invention will be described by way of example and with reference to the accompanying drawings, in which: -
Figure 1 illustrates a cross-section of a prior art fire resistant cable.
Figure 2 shows in more detail the prior art method of bonding the metallic tape around the inner conductors.
Figure 3 illustrates a cross-sectional view of the present invention.
Figure 4 shows in greater detail how the edges of the metallic tape may be folded and rolled internally to prevent the metallic tape opening in a fire condition.
Figure 5 illustrates a cross-sectional view of an embodiment whereby the edges of the metallic tape may be folded and rolled only once.
Referring now to the drawings, the implementation of the present invention is illustrated in Figures 3 and 4. In use, the fire resistant cable comprises at least one electrical conductor 20, which is insulated against other conductors 20 and the metallic tape 26 using an insulating sheath 24 which may comprise silicon rubber or any suitable polymer-based insulator
having a unitary cross section. Typically, annealed copper is utilised for the electrical conductors 20 and for the uninsulated circuit protective conductor 22, which is also bonded to the metallic tape 26.
The metallic tape 26 may be provided using copper or aluminium or any other suitable metallic foil. Bonded around the metallic tape 26 is a fire resistant protective outer sheath 28, which is a typically a halogen-free low-smoke insulator.
Figure 4 shows further detail of how the edges of the metallic tape 26 may be folded and rolled to prevent the edges of the metallic tape 26 opening in a fire condition and thus exposing the inner conductors 20, 22. In particular, when the metallic tape 26 is rolled around the inner conductors 20, 22, each longitudinal edge of the metallic tape 26 is then placed into an overlapped abutting configuration. A sealant or other suitable adhesive (not shown) can be used to improve the integrity of the join, although the use of such is not always necessary. From this overlapped abutting configuration, both edges of the metallic tape 26 are then rolled inwardly through an angle of at least 180° in what may be thought of as a 'crimp' arrangement, and which effectively strengthens the joint. In the preferred embodiment shown in Figures 3 and 4, the step of rolling the both longitudinal edges of the metallic tape 26 inwardly through an angle of at least 180° is repeated, such that the total angle of rotation of the joint is 360° or 540° or more. In this manner, the metallic tape 26 encasing the inner conductors 20, 22 is much more likely to stay intact during a fire and water condition. The final step in the procedure involves bonding the fire resistant protective outer sheath 28 around the metallic tape 26.
The advantage of such an inwardly facing joint between the longitudinal edges of the metallic tape 26 is that even after prolonged exposure to fire and water, the metallic tape 26 stays intact and thus the inner conductors 20, 22 do not experience the full effects of fire and water, and electrical integrity of
the inner conductors 20, 22 is maintained. In this way, any suitable insulating material may be used for the inner insulating sheath 24. The inward nature of the joint also ensures that the outer circumference of the metallic tape 26 is substantially cylindrical in cross-section, so as to increase the overall durability of the cable. The inwardly facing nature of the joint also falls neatly in the gap between neighbouring inner conductors 20, 22.
The inwardly facing joint between the longitudinal edges of the metallic tape 26 also ensures that a very strong mechanical strength cable is provided which is still reasonably pliable, and which can be easily bent into, for example, small radius bends during installation. The cable as shown in Figures 3 and 4 is therefore capable of meeting the requirements of BS 5839 Part 1 : 2002 Clause 26.2 for both standard and enhanced fire resistant cables.
Figure 5 shows an embodiment of the invention whereby the joint between the longitudinal edges of the metallic tape 26 is folded and then rolled only once substantially through 180° to provide an 'interlock' or 'crimp' arrangement, prior to bonding the fire resistant protective outer sheath 28 around the metallic tape 26. Such a fire resistant cable will not have such a high mechanical strength as the cable shown in Figures 3 and 4, although such will more pliable and capable of at least meeting the requirements of BS 5839 Part 1 : 2002 Clause 26.2 for standard fire resistant cables.
Various alterations and modifications may be made to the present invention without departing from the scope of the invention. For example, although particular embodiments refer to a fire resistant cable for use in critical and emergency signal paths, this is in no way intended to be limiting as, in use, the present invention may be implemented in a variety of applications where a certain level of fire resistance and/or mechanical integrity is desired, such as electrical power systems or telecommunications, etc. The manner in which the metallic tape 26 is folded may also have further
application in neighbouring technical fields. Although the present application refers to various British Standards, these are for illustrative purposes only, as, in use, differing standards for the fire resistance of cables are specified in other countries.