Description: FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

TITLE OF THE INVENTION

“Water swellable fiber reinforced plastic (FRP) rod and method for preparation thereof”

APPLICANT:

Name : Runaya private limited

Nationality : Indian

Address : Village Galonda, 374/1 , Silvassa
U.T of Dadra and Nager Haveli, India, pin 396230

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

FIELD OF INVENTION
[0001] The present disclosure relates to a fiber optic cable having water swellable fiber reinforced plastic (FRP) rod. More specifically, it relates to a method and system for preparing the water swellable FRP.

BACKGROUND
[0002] Generally, fiber optical cables pass through thousands of kilometers in different surfaces such as land surface, and water surface. There is a possibility that water may be introduced into the fiber optic cables which can deteriorate transmission capabilities of the fiber optical cables. To prevent such degradation, water blocking has historically been accomplished in the fiber optic cables by using water blocking yarns circumferentially wounded around central strength member of the fiber optical cables, and water blocking powder embedded in interstitial spaces between the buffer tubes containing optical fibers units and center strength members.
[0003] However, usage of the yarns and the water blocking powder in the fiber optical cables, increases size of the fiber optical cables. In order to compensate for the increase in size of the fiber optical cables and to have easier installation, manufacturers have reduced size of cabling to reduce bulk which will reduce signal quality.
[0004] Thus, it is desired to address the above mentioned disadvantages or other shortcomings or at least provide a useful alternative.

OBJECT OF INVENTION
[0005] The principal object of the embodiments herein is to provide a method of preparing a water swellable fiber reinforced plastic (FRP) rod which is used as strength member in optical fiber cable. The method comprises providing an FRP rod and passing the FRP rod through a container to obtain a Super Absorbent Powder (SAP) impinged FRP rod. The method also comprises curing the SAP impinged FRP rod in an ultraviolet (UV) chamber to obtain the water swellable FRP rod.
[0006] Another object of the embodiments herein is to provide a device to prepare the water swellable fiber reinforced plastic (FRP) rod. The device comprises a container configured to receive an FRP rod and provide a super absorbent powder (SAP) impinged FRP rod by impregnating the FRP rod, and an ultraviolet (UV) chamber configured to receive the SAP impinged FRP rod and provide the water swellable FRP rod by curing the SAP impinged FRP rod.
[0007] Another object of the embodiments herein is to provide an optical fiber cable having the water swellable FRP. The optical fiber cable comprises a plurality of one or more optical fibers and a buffer tubes enclosing the one or more of optical fibers. The optical fiber cable also comprises one or more water swellable FRP rods positioned in the center or embedded between High Density Polyethylene (HDPE) jacket of the optical fiber cable.
SUMMARY
[0008] Embodiments herein disclose an optical fiber cable. The optical cable comprises a plurality of one or more optical fibers and a buffer tubers enclosing the one or more of optical fibers. The optical fiber cable also comprises one or more water swellable FRP rods positioned in a center or embedded between high density polyethylene (HDPE) jacket of the optical fiber cable. The optical fiber cable also comprises a binder film enclosing the plurality of one or more optical fibers and the water swellable FRP rod.
[0009] In an embodiment, the one or more water swellable FRP rods is prepared by providing an FRP rod, passing the FRP rod through a container to obtain a super absorbent powder (SAP) impinged FRP rod, and curing the SAP impinged FRP rod in an ultraviolet (UV) chamber to obtain the water swellable FRP rod.
[0010] In an embodiment, the FRP rod is an uncured FRP rod and the container is a pressurized chamber that includes a super absorbent powder (SAP) particles to impregnate the FRP rod with the SAP particles.
[0011] In an embodiment, the FRP rod is a partially cured FRP rod and passing the FRP rod through the container to obtain the SAP impinged FRP rod comprises preparing a mixture of a super absorbent powder (SAP) particles and a blend of epoxy resin and hardener and providing the mixture in the container, wherein the container is a resin tank. Further, passing the partially cured FRP rod through the resin tank to obtain the SAP impinged FRP rod by impregnating the partially cured FRP rod with the mixture.
[0012] In an embodiment, the one or more water swellable FRP rods are positioned at a center of the optical fiber cable.
[0013] In an embodiment, the one or more water swellable FRP rods are embedded in high density polyethylene (HDPE) jacket of the optical fiber cable.
[0014] Embodiments herein discloses a method of preparing a water swellable fiber reinforced plastic (FRP) rod. The method comprises providing an FRP rod, and passing the FRP rod through a container to obtain SAP impinged FRP rod. The method also comprises curing the SAP impinged FRP rod in a ultraviolet (UV) chamber to obtain the water swellable FRP rod.
[0015] In an embodiment, the FRP rod is an uncured FRP rod and passing the FRP rod through the container to obtain the SAP impinged FRP rod comprises passing the FRP rod through the container to obtain SAP impinged FRP rod. The container is a pressurized chamber that includes super absorbent powder (SAP) particles to impregnate the uncured FRP rod with the SAP particles.
[0016] In an embodiment, the FRP rod is a partially cured FRP rod and passing the FRP rod through the container comprises preparing a mixture of a super absorbent powder (SAP) particles and a blend of epoxy resin and hardener and providing the mixture in the container, wherein the container is a resin tank. Further, passing comprises passing the partially cured FRP through the resin tank to obtain the SAP impinged FRP rod by impregnating the partially cured FRP rod with the mixture.
[0001] In an embodiment, the SAP particles include sodium polyacrylate water swellable powder, wherein a quantity of the SAP particles is at least 1 grams/meter, wherein a size of the SAP particles is varying from 200 µm to 400 µm, and wherein a density of the SAP particles is varying from 0.60 g/cu.cm to 0.80 g/ cu.cm.
[0002] In an embodiment, the SAP impinged FRP rod is cured in the UV chamber at a temperature of 90?.
[0003] In an embodiment, the FRP rod includes inorganic E glass/ H glass roving having elastic modulus greater than 50 Gpa, and wherein a diameter of individual filaments of the inorganic E glass/ H glass roving is varying from 16.0 µm – 18.0 µm.
[0004] In an embodiment, a pressure within the pressurized chamber is maintained at less than 6 bar.
[0005] In an embodiment, the mixture is prepared at a shear rate for about 3 hours approximately at 100 rpm in an internal mixer.
[0006] Embodiments herein discloses a device to prepare a water swellable fiber reinforced plastic (FRP) rod. The device comprises a container configured to receive an FRP rod and provide a SAP impinged FRP rod by impregnating the FRP rod, and a ultraviolet (UV) chamber configured to receive the SAP impinged FRP rod and provide the water swellable FRP rod by curing the SAP impinged FRP rod.
[0007] In an embodiment, the FRP rod is an uncured FRP rod and the container is a pressurized chamber that includes super absorbent powder (SAP) particles to impregnate the uncured FRP rod with the SAP particles.
[0008] In an embodiment, the FRP rod is a partially cured FRP rod and the container includes a mixture component configured to receive super absorbent powder (SAP) particles and a blend of epoxy resin and hardener, and to provide to a mixture of the SAP particles and the epoxy resin. The container also includes a resin tank configured to receive the mixture of the SAP particles and the epoxy resin, and to provide the SAP impinged FRP rod on dipping in the container.
[0009] In an embodiment, the SAP particles include sodium polyacrylate water swellable powder, a quantity of the SAP particles is at least 1 grams/meter, a size of the SAP particles is varying from 200 µm to 400 µm, and a density of the SAP particles is varying from 0.60 g/cu.cm to 0.80 g/ cu.cm.
[0010] In an embodiment, the UV chamber configured to cure the SAP impinged FRP rod at a temperature of 90?.
[0011] In an embodiment, the FRP rod includes inorganic E glass/ H glass roving having elastic modulus greater than 50 Gpa, and wherein a diameter of individual filaments of the inorganic E glass/ H glass roving is varying from 16.0 µm – 18.0 µm.
[0012] In an embodiment, the pressurized chamber is maintained at a pressure of less than 6 bar.
[0013] In an embodiment, the mixture unit is configured to prepare the mixture at a shear rate for about 3 hours approximately at 100 rpm in an internal mixer.
[0014] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES
[0015] This method and system is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0016] FIG. 1 illustrates a sectional view of an exemplary fiber optic cable having water swellable fiber reinforced plastic (FRP) rod according to the embodiments as disclosed herein;
[0017] FIG. 2 illustrates a sectional view of another exemplary fiber optic cable having water swellable fiber reinforced plastic (FRP) rod according to the embodiments as disclosed herein;
[0018] FIG. 3A illustrates an exemplary device for preparing a water swellable fiber reinforced plastic (FRP) rod using a chemical adsorption process according to the embodiments as disclosed herein;
[0019] FIG. 3B illustrates an exemplary device for preparing a water swellable fiber reinforced plastic (FRP) rod using a physical adsorption process according to the embodiments as disclosed herein;
[0020] FIG. 4 illustrates an exemplary flowchart showing a method of preparing water swellable fiber reinforced plastic (FRP) rod according to the embodiments as disclosed herein; and
[0021] FIGS. 5A and 5B illustrate an exemplary water swellable fiber reinforced plastic (FRP) rod when placed without water and with water immersion according to the embodiments as disclosed herein.

DETAILED DESCRIPTION OF INVENTION
[0022] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments. The term “or” as used herein, refers to a non-exclusive or, unless otherwise indicated. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those skilled in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0023] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any alterations, equivalents and substitutes in addition to those which are particularly set out in the accompanying drawings. Although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are generally only used to distinguish one element from another.
[0024] Embodiments herein disclose an optical fiber cable. The optical cable comprises a plurality of one or more optical fibers and a buffer tubes enclosing the one or more of optical fibers. The optical cable also comprises one or more water swellable FRP rods positioned in a center or embedded between high density polyethylene (HDPE) jacket of the optical fiber cable. The optical fiber cable also comprises a binder film enclosing the plurality of one or more optical fibers and the water swellable FRP rod.
[0025] Embodiments herein discloses a method of preparing a water swellable FRP rod. The method comprises providing an FRP rod, and passing the FRP rod through a container to obtain a SAP impinged FRP rod. The method also comprises curing the SAP impinged FRP rod in ultraviolet (UV) chamber to obtain the water swellable FRP rod.
[0026] Embodiments herein discloses a device to prepare a water swellable FRP rod. The device comprises a container configured to receive an FRP rod and provide a SAP impinged FRP rod by impregnating the FRP rod, and an ultraviolet (UV) chamber configured to receive the SAP impinged FRP rod and provide the water swellable FRP rod by curing the SAP impinged FRP rod.
[0027] In the conventional methods and systems, to prevent degradation of optical cables due to water entering into the optical fiber cables, water blocking yarns and powder has been accomplished in the optic fiber cables by using yarns circumferentially wounded around central strength member of the fiber optical cables, and water blocking powder embedded in interstitial spaces between the buffer tubes containing optical fibers units and center core members. However, usage of the yarns and the water blocking powder in the fiber optical cables, increases size of the fiber optical cables. In order to compensate for the increase in size of the fiber optical cables and to have easier installation, manufacturers have reduced size of cabling as per specific application of the end user to reduce bulk which will reduce signal quality.
[0028] Unlike to the conventional methods and systems, in the present disclosure by the usage of water swellable fiber reinforced plastic (FRP) rod, yarns which are used in the conventional methods can be completely eliminated.
[0029] Referring now to the drawings, and more particularly to FIGS. 1 through 5B, where similar reference characters denote corresponding features consistently throughout the figures, there are shown preferred embodiments.
[0030] FIG. 1 illustrates a sectional view of an exemplary fiber optic cable having water swellable fiber reinforced plastic (FRP) rod according to the embodiments as disclosed herein. As shown in figure 1, the optical cable 100 comprise an outer jacket 101, one or more buffer tubes 103, a water swellable fiber reinforced plastic (FRP) rod 105, optical fiber units 107, and a binder film 109.
[0031] The outer jacket 101 is typically made of a variety of polymeric materials such as for example but not limited to polyvinylchloride (PVC), polyurethane, fluoropolymer, polyethylene, ethylene-vinyl–acetate, flame retardant PVC, low smoke zero halogen material, or a combination of suitable materials which comes in to contact with outside environment. The outer jacket 101 may include a wide variety of suitable shapes and/ or dimensions. In one embodiment, the outer jacket 101 may be formed to result in a round cable or a cable having an appropriate round cross section. In other embodiment, the outer jacket 101 may be formed to result in other desired shapes such as elliptical shape or circular shape. The one or more buffer tubes 103 is not particularly limited and may include, polyolefin (e.g., polypropylene or polyethylene) or polyesters (e.g., polybutylene terephthalate).
[0032] The water swellable FRP rod 105 is placed in a center of the optical cable 100 and is used as the central strength member in the optical cable 100. The water swellable FRP rod 105 acts as a moisture barrier in order to provide a protection to the internal components such as optical fiber units 107 of the optical cable 100. The moisture barrier in the optical cable 100 containing more than one optical fiber is typically provided to reduce moisture penetration that destroy or weaken the optical fiber units 107 resulting in signal attenuation. The water swellable FRP rod 105 is manufactured using the process as detailed in subsequent paragraphs with respect to explanation of Fig. 3A and 3B. The optical fiber units 107 includes a plurality of one or more optical fiber units bundled together for transmission of information. The binder film 109 is used to bind the one or more optical fiber units 107. The optical cable 100 may have a wide variety of dimensions, such as any suitable outside diameter and/or any suitable wall thickness.
[0033] Once the water swellable FRP rod 105 is manufactured, a wide variety of suitable methods/or techniques may be utilized to incorporate the water swellable FRP rod 105 in to the optical cable 100. In one embodiment, the water swellable FRP rod 105 may be applied by physical contact or electrostatic attraction. The optical cable 100 may be passed through the water swellable FRP rod 105, such as electrically charged swellable fibers, and the swellable fibers may temporarily cling to the optical cable 100 prior to the formation of the buffer tubes 103.
[0034] In another embodiment, the water swellable FRP 105 may be incorporated in discontinues manner. The water swellable FRP 105 may be incorporated at regular or irregular intervals to provide water blocking for the optical cable 100.
[0035] FIG. 2 illustrates a sectional view of another exemplary fiber optic cable having water swellable fiber reinforced plastic (FRP) rod according to the embodiments as disclosed herein. As shown in figure 2, the optical cable 200 comprises an outer jacket 201 having one or more water swellable FRP rods 203, and a buffer tube 205 having an optical fiber unit 207 and a super absorbent powder 209.
[0036] The outer jacket 201 is typically made of a variety of polymeric materials such as for example but not limited to polyvinylchloride (PVC), polyurethane, fluoropolymer, polyethylene, ethylene-vinyl–acetate, flame retardant PVC, low smoke zero halogen material, or a combination of suitable materials which comes in to contact with outside environment. The outer jacket 201 may include a wide variety of suitable shapes and or dimensions. In one embodiment, the outer jacket 201 may be formed to result in a round cable or a cable having an appropriate round cross section. The optical cable 200 may be formed to result in other desired shapes such as elliptical shape or circular shape. The optical cable 200 may also have a wide variety of dimensions, such as any suitable outside diameter and/or any suitable wall thickness.
[0037] The water swellable FRP rod 203 acts as a moisture barrier in order to provide protection to the internal components such as optical fiber units 207 of the optical cable 200. The moisture barrier in the optical cable 200 containing more than one optical fiber is typically provided to reduce moisture penetration that destroy or weaken the optical fiber units 207 resulting in signal attenuation. The water swellable FRP rod 203 is manufactured using the process as detailed in subsequent paragraphs with respect to explanation of Figs. 3A and 3B.
[0038] FIG. 3A illustrates an exemplary device for preparing a water swellable fiber reinforced plastic (FRP) rod using a chemical adsorption method according to the embodiments as disclosed herein. As shown in FIG. 3A, the device 300 comprises a storage tank 305, a resin tank 310, and an ultraviolet (UV) chamber 315 to prepare the water swellable FRP rod 322 by incorporating water swellable powders on an outer periphery of a partially cured FRP rod 302.
[0039] In the storage tank 305, a super absorbent powder (SAP) having a concentration of 10.0 wt.% - 15.0 wt.% is mixed in a blend of epoxy resin and hardener at a high shear rate for about less than 3 hours to prepare a mixture. The mixture is poured in the resin tank 310 and the partially cured FRP rod 302 is passed through the resin tank 310. The partially cured FRP rod 302 impinges the SAP powder in its outer periphery when the partially cured FRP rod 302 is passed through the resin tank 310 to obtain a SAP impinged FRP rod 312.
[0040] The SAP impinged FRP rod 312 is then passed through the UV chamber 315 to produce the water swellable FRP rod 322. In one embodiment, the SAP impinged FRP rod 312 is cured in the UV chamber 315 at a temperature of 90?.
[0041] In one embodiment, the water swellable FRP rod 322 is placed in the optical cable 100. The water swellable FRP rod 322 is placed in the center of the optical cable 100 and is used as the central strength member in the optical cable 100. The water swellable FRP rod 322 acts as a moisture barrier in order to provide protection to the internal components such as optical fiber units 106 of the optical cable 100.
[0042] In another embodiment, the water swellable FRP rod 322 is placed in an outer jacket 201 of an optical cable 200. The water swellable FRP rod 322 acts as a moisture barrier in order to provide a protection to the internal components such as optical fiber units 207 of the optical cable 200.
[0043] The water swellable FRP rod 322 prepared using the above mentioned method can be incorporated in a wide variety of cables, such as twisted pair communication cables, power cables, optical fiber cables, and/ or a wide variety of composite cables and other transmission media. Additionally, embodiments of the disclosure may be used in drop cables, vertical cables, riser cables or any other appropriate cables.
[0044] FIG. 3B illustrates an exemplary system for preparing a water swellable fiber reinforced plastic (FRP) rod using a physical adsorption method according to the present invention. As shown in figure 3B, the system 350 comprises a pressurized chamber 355 and an ultraviolet (UV) chamber 360 to prepare the water swellable FRP rod 372 by incorporating water swellable powders on an outer periphery of an uncured FRP rod 352.
[0045] The uncured FRP rod 352 is initially passed through a pressurized chamber 355. In one embodiment, the pressurized chamber 355 is maintained at less than 6 bar, and capacity of less than 1 liter. In the pressurized chamber 355, the super absorbent powder (SAP) is circulated by air flow. The uncured FRP rod 352 comes in to contact with the SAP particles which gets deposited on the outer periphery of the uncured FRP rod 352 to provide SAP impinged FRP rod 362.
[0046] The SAP impinged FRP rod 362 is then passed through the UV chamber 360 to produce the water swellable FRP rod 372. In one embodiment, the SAP impinged FRP rod 362 is cured in the UV chamber 360 at a temperature of 90?.
[0047] The water swellable FRP rod 372 prepared using the above mentioned method can be incorporated in a wide variety of cables, such as twisted pair communication cables, power cables, optical fiber cables, and/ or a wide variety of composite cables and other transmission media. Additionally, embodiments of the disclosure may be used in drop cables, vertical cables, riser cables or any other appropriate cables.
[0048] In one embodiment, partially cured FRP rods are passed through a dip tank for coating the partially cured FRP in order to provide better surface glossiness and to lower roughness of the FRP rod. The water swellable FRP rod 372 has mat finish where the SAP powders are homogeneously covered, and swells by not less than 10.0% by increase in the diameter of the rod when the water swellable FRP rod 372 comes in contact with water.
[0049] FIG. 4 illustrates an exemplary flowchart showing a method for preparing water swellable FRP according to the embodiments as disclosed herein.
[0050] As illustrated in FIG. 4, the method 400 comprises one or more blocks for preparing the water swellable FRP rod. The order in which the method 400 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 400. Additionally, individual blocks may be deleted from the method 400 without departing from the spirit and scope of the subject matter described herein.
[0051] At block 402, an FRP rod is provided. In one embodiment, the FRP rod is partially cured rod 302 that is provided for preparing the water swellable FRP rod 322. In another embodiment, the FRP rod is an uncured FRP rod that is provided for preparing the water swellable FRP rod 372. The FRP rod that is provided includes inorganic E glass/ H glass roving having elastic modulus greater than 50 Gpa, and a diameter of individual filaments of the inorganic E glass/ H glass roving generally varies from 16.0 µm – 18.0 µm.
[0052] At block 404, the FRP rod is passed through a container to obtain a Super Absorbent Powder (SAP) impinged FRP rod. In one embodiment, the uncured FRP rod 352 is passed through the container which is a pressurized chamber 355. The pressurized chamber 355 includes super absorbent powder (SAP) particles to impregnate the uncured FRP rod 352 with the SAP particles. The SAP particles generally include, but not limited to, sodium polyacrylate water swellable powder and a quantity of the SAP particles is at least 1 grams/meter. In an exemplary embodiment, a size of the SAP particles is varying from 200 µm to 400 µm, and a density of the SAP particles is varying from 0.60 g/cu.cm to 0.80 g/ cu.cm.
[0053] In another embodiment, the partially cured FRP rod 302 is passed through a container to obtain SAP impinged FRP rod 312 includes a prior step of preparing a mixture of a super absorbent powder (SAP) particles and a blend of epoxy resin and hardener and providing the mixture in the container. Upon the mixture is provided in the container which is a resin tank 310, the partially cured FRP rod 302 is passed through the resin tank 310 to obtain the SAP impinged FRP rod 312 by impregnating the uncured FRP rod 302 with the mixture. Generally, the mixture is prepared at a shear rate for about 3 hours approximately at 100 rpm in an internal mixer.
[0054] At block 406, the SAP impinged FRP rod 312, 362 is cured in an ultraviolet (UV) chamber 315, 360 to obtain the water swellable FRP rod 322, 372. The SAP impinged FRP rod 312, 362 which is obtained either from the resin tank 310 or pressurized chamber 355 is cured through the UV chamber 315, 360 to obtain the water swellable FRP rod 322, 372. In one embodiment, the UV chamber 315, 360 is maintained at a temperature of 90? to cure the SAP impinged FRP rod 312, 362 for obtaining the water swellable FRP rod 322, 372.
[0055] In one embodiment, partially cured FRP rods are passed through a dip tank for coating the partially cured FRP in order to provide better surface glossiness and to lower roughness of the FRP rod. The water swellable FRP rod has mat finish where the SAP powders are homogeneously covered, and swells by not less than 10.0% by increase in the diameter of the rod when the water swellable FRP rod 105, 205 comes in contact with water.
[0056] The water swellable FRP rod 322, 372 prepared using the above mentioned method can be incorporated in a wide variety of cables, such as twisted pair communication cables, power cables, optical fiber cables, and/ or a wide variety of composite cables and other transmission media. Additionally, embodiments of the disclosure may be used in drop cables, vertical cables, riser cables or any other appropriate cables.
[0057] FIG. 5A and FIG. 5B illustrate an exemplary water swellable FRP when placed without water and with water immersion in accordance with an embodiment of the present disclosure.
[0058] The water swellable FRP rod 105, 205 when placed without contact with water is depicted in Figure 5A.
[0059] The water swellable FRP rod 105, 205 swollen upon contact with water is depicted in Figure 5B.
[0060] The water swellable FRP rod may be incorporated into the optical cable and helps in the reduction of use of tape, a yarn, or another substrate. In certain embodiments, the diameter and/ or other relevant dimension of the cable can also be reduced. Additionally, in certain embodiments the use of water swellable FRP rod may permit the formation of relatively dry cable. Further, the cable formed can be free of fluids or gels, such as water blocking gels.
[0061] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the scope of the embodiments as described herein.
, Claims: CLAIMS

We Claim:

1. An optical cable, comprising:
a plurality of one or more optical fibers;
a buffer tube enclosing the one or more of optical fibers;
one or more water swellable fiber reinforced plastic (FRP) rods positioned between the plurality of one or more optical fibers; and
a binder film enclosing the plurality of one or more optical fibers.

2. The optical fiber cable as claimed in claim 1, wherein the one or more water swellable FRP rods is prepared by:
providing an FRP rod;
passing the FRP rod through a container to obtain a Super Absorbent Powder (SAP) impinged FRP rod; and
curing the SAP impinged FRP rod in an ultraviolet (UV) chamber to obtain the water swellable FRP rod.

3. The optical fiber cable as claimed in claim 2, wherein the FRP rod is an uncured FRP rod, and wherein the container is a pressurized chamber that includes super absorbent powder (SAP) particles to impregnate the FRP rod with the SAP particles.

4. The optical fiber cable as claimed in claim 2, wherein the FRP rod is a partially cured FRP rod, and wherein passing the FRP rod through the container to obtain the SAP impinged FRP rod comprises:
preparing a mixture of a super absorbent powder (SAP) particles and a blend of epoxy resin and hardener;
providing the mixture in the container, wherein the container is a resin tank; and
passing the partially cured FRP rod through the resin tank to obtain the SAP impinged FRP rod by impregnating the partially cured FRP rod with the mixture.

5. The optical fiber cable as claimed in claim 1, wherein the one or more water swellable FRP rod are positioned at a center of the optical cable.

6. The optical fiber cable as claimed in claim 1, wherein the one or more water swellable FRP rods are embedded in an outer jacket of the optical cable.

7. A method of preparing a water swellable fiber reinforced plastic (FRP) rod, the method comprising:
providing an FRP rod;
passing the FRP rod through a container to obtain a Super Absorbent Powder (SAP) impinged FRP rod; and
curing the impinged FRP rod in a ultraviolet (UV) chamber to obtain the water swellable FRP rod.

8. The method as claimed in claim 7, wherein the FRP rod is an uncured FRP rod, and wherein passing the FRP rod through the container to obtain the SAP impinged FRP rod comprises:
passing the uncured FRP rod through the container to obtain SAP impinged FRP rod, wherein the container is a pressurized chamber that includes super absorbent powder (SAP) particles to impregnate the uncured FRP rod with the SAP particles.

9. The method as claimed in claim 7, wherein the FRP rod is a partially cured FRP rod, and wherein passing the FRP rod through the container to obtain the SAP impinged FRP rod comprises:
preparing a mixture of a super absorbent powder (SAP) particles and a blend of epoxy resin and hardener;
providing the mixture in the container, wherein the container is a resin tank; and
passing the partially cured FRP rod through the resin tank to obtain the SAP impinged FRP rod by impregnating the partially cured FRP rod with the mixture.

10. The method as claimed in claim 8 or 9, wherein the SAP particles include sodium polyacrylate water swellable powder, wherein a quantity of the SAP particles is at least 1 grams/meter, wherein a size of the SAP particles is varying from 200 µm to 400 µm, and wherein a density of the SAP particles is varying from 0.60 g/cu.cm to 0.80 g/ cu.cm.

11. The method as claimed in claim 7, wherein the SAP impinged FRP rod is cured in the UV chamber at a temperature of 90?.

12. The method as claimed in claim 7, wherein the FRP rod includes inorganic E glass/ H glass roving having elastic modulus greater than 50 Gpa, and wherein a diameter of individual filaments of the inorganic E glass/ H glass roving is varying from 16.0 µm – 18.0 µm.

13. The method as claimed in claim 8, wherein a pressure within the pressurized chamber is maintained at less than 6 bar.

14. The method as claimed in claim 9, wherein the mixture is prepared at a shear rate for about 3 hours approximately at 100 rpm in an internal mixer.

15. A device to prepare a water swellable fiber reinforced plastic (FRP) rod, the device comprises:
a container configured to receive an FRP rod and provide a Super Absorbent Powder (SAP) impinged FRP rod by impregnating the FRP rod; and
an ultraviolet (UV) chamber configured to receive the SAP impinged FRP rod and provide the water swellable FRP rod by curing the SAP impinged FRP rod.

16. The device as claimed in claim 15, wherein the FRP rod is an uncured FRP rod, and wherein the container is a pressurized chamber that includes super absorbent powder (SAP) particles to impregnate the uncured FRP rod with the SAP particles.

17. The device as claimed in claim 15, wherein the FRP rod is a partially cured FRP rod, and wherein the container includes:
a mixture component configured to receive super absorbent powder (SAP) particles and a blend of epoxy resin and hardener, and to provide to a mixture of the SAP particles and the epoxy resin; and
a resin tank configured to receive the mixture of the SAP particles and the epoxy resin, and to provide the SAP impinged FRP rod by impregnating the partially cured FRP rod with the mixture.

18. The device as claimed in claim 16 or 17, wherein the SAP particles include sodium polyacrylate water swellable powder, wherein a quantity of the SAP particles is at least 1 grams/meter, wherein a size of the SAP particles is varying from 200 µm to 400 µm, and wherein a density of the SAP particles is varying from 0.60 g/cu.cm to 0.80 g/ cu.cm.

19. The device as claimed in claim 15, wherein the UV chamber configured to cure the SAP impinged FRP rod at a temperature of 90?.

20. The device as claimed in claim 15, wherein the FRP rod includes inorganic E glass/ H glass roving having elastic modulus greater than 50 Gpa, and wherein a diameter of individual filaments of the inorganic E glass/ H glass roving is varying from 16.0 µm – 18.0 µm.

21. The device as claimed in claim 16, wherein the pressurized chamber is maintained at a pressure of less than 6 bar.

22. The device as claimed in claim 17, wherein the mixture unit is configured to prepare the mixture at a shear rate for about 3 hours approximately at 100 rpm in an internal mixer.