Compact, Hybrid Fiber Reinforced Rods For Optical Cable Reinforcements And Method For Making Same

Abstract

Fiber reinforcement rods having a combination of reinforcing fiber members coated with a UV curable vinyl ester resin material and a polybutylene terephthalate/polyether glycol or ethylene acrylic acid topcoat layer. The reinforcing fiber members may be S-type fiber members, E-type glass fiber members, a combination thereof, or E-type glass fiber members and/or S-type glass fiber members with high strength synthetic strands of poly(p-phenylene 2,6 benzoisoxazole fiber members. The topcoat layer provides enhanced properties of specific adhesion, enhanced environmental protection, resistance to surface fiber breakage, and to some degree resistance from delamination.

1 - 6 . (canceled) 
     
     
         23 - 28 . (canceled) 
     
     
         31 . (canceled) 
     
     
         33 . (canceled) 
     
     
         35 - 36 . (canceled) 
     
     
         38 - 39 . (canceled) 
     
     
         41 - 42 . (canceled) 
     
     
         44 - 46 . (canceled) 
     
     
         63 . (canceled) 
     
     
         64 . A method for forming a fiber reinforcement rod comprising:
 providing a plurality of elongated fiber members;   introducing said plurality of fiber members under tension to a heated resin spray applicator;   coating said plurality of fiber members with a UV curable vinyl ester resin material within said heated resin spray applicator, wherein said UV curable vinyl ester resin material is applied at a temperature between approximately 65 and 100 degrees Celsius;   curing said UV curable vinyl ester resin material onto and around said plurality of fiber members using a ultraviolet light source to form a fiber reinforcement rod precursor;   introducing said fiber reinforcement rod precursor to a top coat application box;   encasing said fiber reinforcement rod precursor with a topcoat material layer, wherein said topcoat material layer is applied in said topcoat application box at between approximately 150 and 230 degrees Celsius; and   cooling said topcoat material layer in a water bath.   
     
     
         65 . The method of  claim 64 , wherein providing a plurality of elongated fiber members comprises providing a plurality of elongated fiber members selected from the group consisting of E-type glass fiber members, S-type glass fiber members, high strength synthetic strands of poly(p-phenylene-2,6- benzobisoxazole) fiber members, and combinations thereof 
     
     
         66 . The method of  claim 64  wherein coating said plurality of fiber members comprises coating said plurality of fiber members with a UV curable vinyl ester resin material, wherein said UV curable vinyl ester resin material is a UV curable co polymer of novolac vinyl ester and one of 1,6 hexane diol diacrylate and diprophylene glycol diacrylate. 
     
     
         67 . The method of  claim 64 , wherein encasing said fiber reinforcement rod precursor with a topcoat material layer comprises coating said fiber reinforcement rod precursor with a topcoat material selected from the group consisting of a polybutylene terephthalate/polyether glycolcopolymer topcoat material and an ethylene acrylic acid copolymer topcoat material. 
     
     
         68 . The method of  claim 64 , further comprising one more breaker bars downstream of the heated resin spray applicator, the one or more breaker bars wetting the plurality of elongated fiber members. 
     
     
         69 . The method of  claim 64 , further comprising an UV light source, the UV light source curing said UV curable vinyl ester resin material. 
     
     
         70 . The method of  claim 69 , wherein the UV light source is one of a: ultraviolet light source and a mercury vapor UV light same. 
     
     
         71 . A method of forming an optical fiber cable from a fiber reinforcement rod formed in accordance with the method of  claim 64 , comprising:
 providing the fiber reinforcement rod formed in accordance with the method of claim  1 ;   forming a core assembly by wrapping a plurality of optical fiber member around the fiber reinforcement rod and by wrapping a plurality of buffer tubes around the fiber reinforcement rod;   wrapping the formed core assembly with a plurality of flexible fiber reinforcement members; and   encasing said plurality of flexible fiber reinforcement members and said core assembly with a polymer jacket member.   
     
     
         72 . The method of  claim 71 , wherein he polymer jacket member is applied at approximately 177 degrees Celsius. 
     
     
         73 . The method of  claim 72 , further comprising cooling the polymer jacket by passing the optical fiber cable through a water trough. 
     
     
         74 . The method of  claim 71 , further comprising providing one or more of a water-swellable tape and a water-swellable yarn to said optical fiber cable prior to said encasing with said polymer jacket member. 
     
     
         75 . The method of  claim 71 , further comprising providing a filling compound to said optical fiber cable prior to said encasing with said polymer jacket member.