Fire resistant cable with dual insulation layer arrangement

1. A fire resistant cable comprising:

at least one conductor;

at least one mica layer surrounding and in direct contact with the at least one conductor;

a first layer of insulation surrounding and in direct contact with the at least one mica layer, wherein the first layer of insulation is made of a composition based on a cured flame retardant ceramifiable silicone rubber; and

a second layer of insulation surrounding the first layer of insulation, wherein the second layer of insulation is made of a composition based on a cured flame retardant ceramifiable silicone rubber comprising at least one reinforcement material selected from the group consisting of mica, inorganic fibers, silicon oxide, and titanium oxide.

2. The fire resistant cable of claim 1 , further comprising a jacket layer surrounding the second layer of insulation.

3. The fire resistant cable of claim 2 , wherein the jacket layer is in direct contact with the second layer of insulation.

4. The fire resistant cable of claim 2 , wherein the jacket layer is formed from a low-smoke zero-halogen jacket composition.

5. The fire resistant cable of claim 4 , wherein the jacket composition comprises a polymer material comprising at least one of polyethylene and ethylene vinyl acetate (“EVA”).

6. The fire resistant cable of claim 5 , wherein the jacket composition further comprises from about 40% to about 80%, by weight, of an inorganic halogen-free flame retardant filler.

7. The fire resistant cable of claim 2 maintains circuit integrity during a two-hour burn test at a temperature of at least 1000° C. or greater when tested according to Underwriters Laboratory (“UL”) 2196 (2012).

8. The fire resistant cable of claim 1 , wherein the at least one mica layer comprises two mica layers, such that when applied to the at least one conductors, adjacent windings of the mica layers have an overlap of about 25% or greater.

9. The fire resistant cable of claim 1 , wherein the second layer of insulation is in direct contact with the first layer of insulation.

10. The fire resistant cable of claim 1 , wherein the first layer of insulation and the second layer of insulation are crosslinked.

11. The fire resistant cable of claim 1 , wherein the first layer of insulation and the second layer of insulation each have a thickness from about 15 mils (about 0.4 mm) to about 35 mils (about 0.9 mm).

12. A method of forming a fire resistant cable comprising

providing at least one conductor;

surrounding the at least one conductor with at least one mica layer;

extruding a first layer of insulation around the at least one mica layer, the first layer of insulation being made of a composition based on a cured flame retardant ceramifiable silicone rubber; and

extruding a second layer of insulation around the first layer of insulation, the second layer of insulation being formed from a cured flame retardant ceramifiable silicone rubber comprising at least one reinforcement material selected from the group consisting of mica, inorganic fibers, silicon oxide, and titanium oxide wherein extruding the first layer and extruding the second layer are concurrently carried out; and

curing the first and second layer.

13. The method of claim 12 , further comprising extruding a jacket layer around the second layer of insulation, wherein the first layer of insulation, the second layer of insulation, and the jacket layer are extruded simultaneously via triple extrusion curing the first and second layer.