High performance communications cables supporting low voltage and wireless fidelity applications providing reduced smoke and flame spread

Abstract

The present invention provides conductive and/or insulative compositions comprising polymer blends that include olefin and/or fluoropolymer and/or chlorofluoropolymer based resins with and without inorganic additives. These compositions reduce flammability and smoke generation and are used primarily for insulation materials and for high performance communications cables. In addition, support-separators using these same compositions, to be used within the communications cables, and normally within the cable core, are described. These unique compositions include polymer blends that offer both flame and smoke suppression while maintaining the characteristics necessary to improve electrical performance and allow for severe cost reduction over conventional separators. These polymers blends can also be utilized for fabricating shielding materials. The specially shaped core support-separators can be either interior to the cable jacket or be employed singularly without the benefit of a jacket and extend along the longitudinal length of the communications cable. Alternatively, if no jacket is used for cable completion, a portion of the separator with a thin layer of material surrounding the separator core can act as a type of skin for mechanical protection. Specially shaped core support-separators have both a central region as well as a plurality of shaped sections that extend outward from the central region for which the materials of construction are either solid or partially solid, foamed or foamed with a solid skin surface.

1 . A composition comprising a combination of inorganic fillers or additives including inorganic polymers and organic polymers which are halogenated; said organic polymers of said composition including any combination of; polyvinylchloride (PVC), polyvinylidene chloride (PVDC), polyvinylidene fluoride (PVDF), ethylchlorotetrafluoroethylene (ECTFE), fluorinated ethylene propylene (FEP), and MFA (copolymers of tetrafluoroethylene and perfluoromethylvinyl ether), wherein said fillers include nano-composites of clay and other inorganic fillers including any combination of ZnO, TiO 2 , CaCO 3 , MgCO 3 , talc, ammonium octyl molybdates (AOM), magnesium hydroxide, molbdate complexes including calcium molybdate, molybdenum oxide, and zinc molybdate, and phosphate complexes including ammonium phosphate and melamine phosphate, wherein said fillers are added either individually or in combination with said composition. 
     
     
         2 . The composition of  claim 1 , wherein said organic polymers include any combination of non-halogenated polymers comprising solid and/or foamed polyethylene or polypropylene, solid and/or foamed polyurethane, and silicone polymers including hexamethyldisiloxane, octamethyltrisiloxane, and decamethyltetrasiloxane. 
     
     
         3 . The composition of  claim 1 , wherein said fillers including said inorganic polymers are nano-sized particles and wherein said particles provide unique properties allowing for maintaining electrical integrity and shielding effectiveness between cable pairs and/or between adjacent cables and provides reduction in flame retardance and increased smoke suppression. 
     
     
         4 . The composition of  claim 1 , wherein said organic polymers include particles comprising insulative or semi-conductive Buckminster fullerenes and/or doped fullerenes of the C 60  family providing, during combustion of said composition, reduction in flame generation, reduction in flame spread, increased smoke suppression, and increased char formation. 
     
     
         5 . The composition of  claim 1 , wherein said composition also comprises an outer surface layer and an inner surface layer, wherein said outer surface layer includes either a foamed and/or expanded polyolefin material or a halogenated polymer, such that said outer surface layer assists in forming an intumescent char in the presence of combustion thereby further increasing flame retardancy and wherein said inner layer is capable of withstanding extrusion of said outer layer onto said inner layer without causing said inner layer to decompose. 
     
     
         6 . The composition of  claim 5 , wherein said composition also includes organic/inorganic polymer blends providing further enhanced flame and smoke suppression, electrical performance, and severe cost reduction in manufacturing high performance communications cables. 
     
     
         7 . The composition of  claim 6 , wherein said composition comprises a high performance communications cable with one or more interior support-separator section(s) comprising a longitudinal length and with external radial and axial surfaces having a central region extending along said longitudinal length of said interior support-separator section(s) wherein one or more central regions of the support-separator includes sections that are hollow and wherein said support-separator is jacketed, thereby allowing for completion of said cable. 
     
     
         8 . The composition of  claim 7 , wherein a portion of said interior support-separator includes the additional of a thin layer of material that acts as a type of skin for mechanical protection and wherein said support-separator is solid, partially solid, foamed, or foamed with a solid skin surface. 
     
     
         9 . The composition of  claim 5 , wherein said blends include fluoropolymers that are primarily blended with polyolefins and wherein said blends include metal oxides, said oxides imparting both insulative, semi-conductive, and flame and smoke suppression properties to said composition. 
     
     
         10 . The composition of  claim 5 , wherein a primarily non-halogenated polymer blend comprises inorganic polymers or particles that reduce flammability and increase smoke suppression sufficient for meeting or exceeding NFPA 255 and NFPA 259 test protocols U.L. 910/CSA FT-6, riser cable test U.L. 1666, international fire test IEC 332-3, and the IEEE 383/U.L. 1581 test. 
     
     
         11 . The composition of  claim 5 , wherein a primarily fluoropolymer based blend comprises inorganic substances that reduce flammability and increases smoke suppression sufficient for meeting or exceeding NFPA 255 and NFPA 259 test protocols, U.L. 910/CSA FT-6, riser cable test U.L. 1666, international fire test IEC 332-3, and the IEEE 383/U.L. 1581 test. 
     
     
         12 . The composition of  claim 1 , wherein said composition comprises tapes, polymeric binding sheets, or other means in lieu of extruded thermoplastic jacketing, and wherein said tapes, sheets, jacketing or said other means are comprised of compositions with reduced halogen content when compared with the halogen content of halogenated polymers absent any fillers. 
     
     
         13 . The composition of  claim 1 , wherein said composition wherein said composition comprises recycled or reground thermoplastics in an amount of up to 100 percent of said composition. 
     
     
         14 . The composition of  claim 1 , wherein said composition includes a combination of solid and/or foamed flame retardant and smoke suppressing polyolefins with fluorinated polymers, and wherein said combination is extruded singularly, coextruded, or extruded in tandem to form articles of manufacture. 
     
     
         15 . The composition of  claim 14 , wherein said articles of manufacture include pellets. 
     
     
         16 . The composition of  claim 1 , wherein said combination is extruded into a crossweb-like shape wherein coextrusion and/or tandem extrusion allows for combining two or more polymers, wherein said polymers would otherwise not be combinable. 
     
     
         17 . The composition of  claim 1  wherein said polyolefins are flame retardant polyethylene/polypropylene copolymers or blends of polyethylene and polypropylene used as an inner layer with an extruded fluorinated ethylene propylene outer layer covering over said flame retardant polyolefins and wherein said polyolefins and said fluorinated ethylene propylene are foamable. 
     
     
         18 . The composition of  claim 17 , wherein foaming is accomplished with a blowing agent, preferably Celogen®, representing primarily activated azodicarbonamides that are nondiscoloring, nonstaining, and odorless foaming agents using nitrogen as a carrier gas. 
     
     
         19 . The composition of  claim 1 , wherein when said composition comprises an inner layer polymer structure, said structure further comprising at least one additive, said at least one additive rendering said inner layer with enhanced flame retardants and smoke suppressants and wherein said at least one additive comprises any of the following; magnesium complexes, molybdate complexes, phosphate complexes, alumina trihydrate, and/or zinc borate. 
     
     
         20 . The inner layer polymer structure of  claim 17 , wherein said magnesium complex is magnesium hydroxide. 
     
     
         21 . The inner layer polymer structure of  claim 17 , wherein said molybdate complex is molybdenum oxide and/or zinc molybdate. 
     
     
         22 . The inner layer polymer structure of  claim 17 , wherein said phosphate complex is ammonium polyphosphate and/or melamine phosphate. 
     
     
         23 . The composition of  claim 17 , wherein said outer layer polymer structure includes additives that are the combination of antimony trioxide and at least one of decachlorodiphenyloxide, chlorinated dioctylphthalate, and chlorinated diisooctylphthalate. 
     
     
         24 . The composition of  claim 1 , wherein when said composition comprises an outer surface layer polymer structure, wherein at least one additive is selected from the group consisting of; antimony trioxide, decabromodiphenyloxide, brominated dioctylphthalate, brominated diisooctylphthalate, decachlorodiphenyloxide, chlorinated dioctylphthalate, chlorinated diisooctylphthalate, magnesium complexes, molybdate complexes, phosphate complexes, alumina trihydrate, and zinc borate. 
     
     
         25 . The composition of  claim 1 , wherein when said composition comprises an inner surface layer polymer structure, wherein at least one additive is selected from the group consisting of; antimony trioxide, decabromodiphenyloxide, brominated dioctylphthalate, brominated diisooctylphthalate, decachlorodiphenyloxide, chlorinated dioctylphthalate, chlorinated diisooctylphthalate, magnesium complexes, molybdate complexes, phosphate complexes, alumina trihydrate, and zinc borate. 
     
     
         26 . The composition of  claim 1 , wherein said one additive is a combination of antimony trioxide and at least one of the following chemical species; decachlorodiphenyloxide, chlorinated dioctylphthalate, and chlorinated diisooctylphthalate. 
     
     
         27 . A method of producing the compositions of  claim 1 , wherein improving both electrical and flammability properties of said compositions comprises irradiation of polyolefins in combination with fluoropolymers by blending of said combination primarily with said polyolefins and additives that include C 60  fullerenes and compounds that incorporate said fullerenes as well as said substituted fullerenes, inorganic clays, and metal oxides. 
     
     
         28 . A high performance communications cable with an interior support, a central region, and outwardly extended portions comprising conductive inorganic fillers or additives or alternatively metallic additives and including shielding around individual conductor pairs or around said interior support such that said cable and associated support, central region and extended portions are capable of lowering to the point of eliminating crosstalk and more specifically lowering alien near end crosstalk (anext) and/or far end crosstalk (FEXT) and wherein said cable is capable of transmission speeds greater than 600 MHz reaching at least 2 GHz. 
     
     
         29 . An interior support-separator for the communications cable of  claim 28 , wherein said interior support, said central region, and said outwardly extended portions are comprised of conductive inorganic fillers or additives or alternatively metallic additives and optionally includes shielding around individual conductor pairs or around said interior support such that said cable and associated support, central region and extended portions are capable of lowering or eliminating crosstalk and more specifically lowering alien near end crosstalk (anext) and/or far end crosstalk (FEXT). 
     
     
         30 . An article comprising a composition with the combination of inorganic fillers or additives including inorganic polymers and organic polymers which are halogenated; said organic polymers of said composition including any combination of polyvinylchloride (PVC), polyvinylidene chloride (PVDC), polyvinylidene fluoride (PVDF), ethylchlorotetrafluoroethylene (ECTFE), fluorinated ethylene propylene (FEP), and MFA (copolymers of tetrafluoroethylene and perfluoromethylvinyl ether), wherein said fillers include nano-composites of clay and other inorganic fillers including any combination of ZnO, TiO 2 , CaCO 3 , MgCO 3 , talc, ammonium octyl molybdates (AOM), magnesium hydroxide, molbdate complexes including calcium molybdate, molybdenum oxide, and zinc molybdate, and phosphate complexes including ammonium phosphate and melamine phosphate, wherein said fillers are added either individually or in combination with said composition. 
     
     
         31 . The article of  claim 30 , wherein said organic polymers include any combination of non-halogenated polymers comprising solid and/or foamed polyethylene or polypropylene, solid and/or foamed polyurethane, and silicone polymers including hexamethyldisiloxane, octamethyltrisiloxane, and decamethyltetrasiloxane. 
     
     
         32 . The article of  claim 30 , wherein said fillers including said inorganic polymers are nano-sized particles and wherein said particles provide unique properties allowing for maintaining electrical integrity and shielding effectiveness between cable pairs and/or between adjacent cables and provides reduction in flame retardance and increased smoke suppression. 
     
     
         33 . The article of  claim 30 , wherein said organic polymers include particles comprising insulative or semi-conductive Buckminster fullerenes and/or doped fullerenes of the C 60  family providing, during combustion of said composition, reduction in flame generation, reduction in flame spread, increased smoke suppression, and increased char formation. 
     
     
         34 . The article of  claim 30 , wherein said composition also comprises an outer surface layer and an inner surface layer, wherein said outer surface layer includes either a foamed and/or expanded polyolefin material or a halogenated polymer, such that said outer surface layer assists in forming an intumescent char in the presence of combustion thereby further increasing flame retardancy and wherein said inner layer is capable of withstanding extrusion of said outer layer onto said inner layer without causing said inner layer to decompose. 
     
     
         35 . The article of  claim 34 , wherein said composition also includes organic/inorganic polymer blends providing further enhanced flame and smoke suppression, electrical performance, and severe cost reduction in manufacturing high performance communications cables. 
     
     
         36 . The article of  claim 35 , wherein said composition comprises a high performance communications cable with one or more interior support-separator section(s) comprising a longitudinal length and with external radial and axial surfaces having a central region extending along said longitudinal length of said interior support-separator section(s) wherein one or more central regions of the support-separator includes sections that are hollow and wherein said support-separator is jacketed, thereby allowing for completion of said cable. 
     
     
         37 . The article of  claim 36 , wherein a portion of said interior support-separator includes the additional of a thin layer of material that acts as a type of skin for mechanical protection and wherein said support-separator is solid, partially solid, foamed, or foamed with a solid skin surface. 
     
     
         38 . The article of  claim 36 , wherein said blends include fluoropolymers that are primarily blended with polyolefins and wherein said blends include metal oxides, said oxides imparting both insulative, semi-conductive, and flame and smoke suppression properties to said composition. 
     
     
         39 . The article of  claim 36 , wherein a primarily non-halogenated polymer blend comprises inorganic polymers or particles that reduce flammability and increase smoke suppression sufficient for meeting or exceeding NFPA 255 and NFPA 259 test protocols U.L. 910/CSA FT-6, riser cable test U.L. 1666, international fire test IEC 332-3, and the IEEE 383/U.L. 1581 test. 
     
     
         40 . The article of  claim 36 , wherein a primarily fluoropolymer based blend comprises inorganic substances that reduce flammability and increases smoke suppression sufficient for meeting or exceeding NFPA 255 and NFPA 259 test protocols, U.L. 910/CSA FT-6, riser cable test U.L. 1666, international fire test IEC 332-3, and the IEEE 383/U.L. 1581 test. 
     
     
         41 . The article of  claim 30 , wherein said composition comprises tapes, polymeric binding sheets, or other means in lieu of extruded thermoplastic jacketing, and wherein said tapes, sheets, jacketing or said other means are comprised of compositions with reduced halogen content when compared with the halogen content of halogenated polymers absent any fillers. 
     
     
         42 . The article of  claim 30 , wherein said composition wherein said composition comprises recycled or reground thermoplastics in an amount of up to 100 percent of said composition. 
     
     
         43 . The article of  claim 30 , wherein said composition includes a combination of solid and/or foamed flame retardant and smoke suppressing polyolefins with fluorinated polymers, and wherein said combination is extruded singularly, coextruded, or extruded in tandem to form articles of manufacture. 
     
     
         44 . The article of  claim 34 , wherein said article of manufacture include pellets. 
     
     
         45 . The article of  claim 30 , wherein said combination is extruded into a crossweb-like shape wherein coextrusion and/or tandem extrusion allows for combining two or more polymers, wherein said polymers would otherwise not be combinable. 
     
     
         46 . The article of  claim 30  wherein said polyolefins are flame retardant polyethylene/polypropylene copolymers or blends of polyethylene and polypropylene used as an inner layer with an extruded fluorinated ethylene propylene outer layer covering over said flame retardant polyolefins and wherein said polyolefins and said fluorinated ethylene propylene are foamable. 
     
     
         47 . The article of  claim 46 , wherein foaming is accomplished with a blowing agent, preferably Celogen®, representing primarily activated azodicarbonamides that are nondiscoloring, nonstaining, and odorless foaming agents using nitrogen as a carrier gas. 
     
     
         48 . The article of  claim 30 , wherein when said composition comprises an inner layer polymer structure, said structure further comprising at least one additive, said at least one additive rendering said inner layer with enhanced flame retardants and smoke suppressants and wherein said at least one additive comprises any of the following; magnesium complexes, molybdate complexes, phosphate complexes, alumina trihydrate, and/or zinc borate. 
     
     
         49 . The inner layer polymer structure of  claim 36 , wherein said magnesium complex is magnesium hydroxide. 
     
     
         50 . The inner layer polymer structure of  claim 36 , wherein said molybdate complex is molybdenum oxide and/or zinc molybdate. 
     
     
         51 . The inner layer polymer structure of  claim 36 , wherein said phosphate complex is ammonium polyphosphate and/or melamine phosphate. 
     
     
         52 . The article of  claim 36 , wherein said outer layer polymer structure includes additives that are the combination of antimony trioxide and at least one of decachlorodiphenyloxide, chlorinated dioctylphthalate, and chlorinated diisooctylphthalate. 
     
     
         53 . The article of  claim 30 , wherein when said composition comprises an outer surface layer polymer structure, wherein at least one additive is selected from the group consisting of; antimony trioxide, decabromodiphenyloxide, brominated dioctylphthalate, brominated diisooctylphthalate, decachlorodiphenyloxide, chlorinated dioctylphthalate, chlorinated diisooctylphthalate, magnesium complexes, molybdate complexes, phosphate complexes, alumina trihydrate, and zinc borate. 
     
     
         54 . The article of  claim 30 , wherein when said composition comprises an inner surface layer polymer structure, wherein at least one additive is selected from the group consisting of antimony trioxide, decabromodiphenyloxide, brominated dioctylphthalate, brominated diisooctylphthalate, decachlorodiphenyloxide, chlorinated dioctylphthalate, chlorinated diisooctylphthalate, magnesium complexes, molybdate complexes, phosphate complexes, alumina trihydrate, and zinc borate. 
     
     
         55 . The composition of  claim 30 , wherein said one additive is a combination of antimony trioxide and at least one of the following chemical species; decachlorodiphenyloxide, chlorinated dioctylphthalate, and chlorinated diisooctylphthalate. 
     
     
         56 . A method of producing the compositions of  claim 30 , wherein improving both electrical and flammability properties of said compositions comprises irradiation of polyolefins in combination with fluoropolymers by blending of said combination primarily with said polyolefins and additives that include C 60  fullerenes and compounds that incorporate said fullerenes as well as said substituted fullerenes, inorganic clays, and metal oxides.