Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Adhesive outermost layer
Reexamination Certificate
1996-11-14
2001-09-04
Allen, Marianne P. (Department: 1631)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Adhesive outermost layer
C428S351000, C428S3550EN, C428S3550RA, C525S329200, C525S329300, C525S330600, C525S919000
Reexamination Certificate
active
06284367
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a process for the preparation of nonwoven water blocking tapes and to the use of such tapes in cable manufacture and, in particular, their use in the manufacture of communications cables using fibre optics. Cables, in particular communication cables using fibre optics, can quickly be damaged by water ingress, particularly if the water travels along the inside of the cable to splices, junctions, signal boosters etc. In the case of underwater or buried cables this problem can be quite serious. The ingress of water into the cable may be simply by the diffusion of water through the outer polymeric jacket, or by rupture of the outer jacket. Rupturing of the outer jacket may be caused by rodent or insect attack, by impact or by abrasion.
PRIOR ART
A number of methods exist for combating this problem. The most widely used approach is to fill the inner regions of the cable with a hydrophobic gel-like compound, such as that sold under the Trade Name Rheogel. This approach suffers from a number of disadvantages, including inefficiency of filling all of the voids within the cable, the process is messy and time consuming, and the adhesion of cable splices is difficult to achieve due to the gel interfering with welding operations or adhesives.
Superabsorbent polymers, e.g. partially crosslinked polymers which absorb many times their own weight in water, and swell considerably without dissolving, to form a gel have also been used. Such superabsorbent polymers have been provided in the form of wide sandwich tapes consisting of a layer of a superabsorbent polymer powder-sandwiched between two layers of a non-woven fabric. Tapes of this type have been described, for example, in U.S. Pat. No. 4,837,077 and EP-A-0024631. However, these products are expensive and cause considerable unwanted increases in cable diameters due to their thickness.
Fibrous substrates with superabsorbent polymer incorporated therein, such as aramid substrates, have also been used, particularly as strengthening wraps for the inner portions of cables. Substrates of this type have been described in EP-A-0482703. However, the methods used to deposit the superabsorbent onto the fibers are not particularly effective and do not result in a high level of superabsorbent on the fibrous substrate. Furthermore, the fibers are not effectively bound together which leads to potential problems of loose fibers during cable assembly processes. Some methods of applying the superabsorbent to the fibers involve the use of organic solvents, with consequential environmental concerns.
In EP-A-0685855 we describe a water blocking composite for use in cables which comprises a strengthening member or buffer tube impregnated with or coated with a mixture of a thermoplastic resin and a water-swellable particulate material. Although these water blocking composites possess certain advantages, they are based on thermoplastic resins which limits their mode of application and the thickness of the coatings that can thereby be applied.
U.S. Pat. No. 5,188,883 discloses a composite tape structure for use in cables having a metal tape layer and a layer of a swellable water blocking material bonded thereto. The layer of water blocking material may be formed from tape impregnated with or provided with a particulate swelling material, or the particulate material may be applied directly to and bonded to the metal tape layer.
U.S. Pat. No. 5,204,175 discloses a water blocking tape made by impregnating a fabric substrate with a metal salt of acrylic acid in monomeric form, a covalent crosslinking agent and a water soluble resin, and then heating the impregnated fabric substrate to copolymerise the monomer and the crosslinking agent in the presence of the water soluble resin.
U.S. Pat. No. 3,966,679 discloses water swellable absorbent articles made from carboxylic polyelectrolytes cross-linked with a crosslinking agent reactive with the carboxylic groups. Suitable crosslinking agents are polyhaloalkanols, sulfonium zwitterions, haloepoxy-alkanes and polyglycidic ethers. Crosslinking agents of this type are disclosed in U.S. Pat. No. 3,926,981. Many of these crosslinking agents are toxic and/or can produce harmful by-products during use. Furthermore, viscosity of the coating formulations is very high which makes it difficult to apply the compositions uniformly. The coating formulations also have a limited shelf life.
U.S. Pat. No. 4,090,013 discloses covalently crosslinked systems which have a limited shelf life and high viscosity.
U.S. Pat. No. 5,280,079 discloses an extruded water absorbent, water insoluble polymeric element that is a crosslinked copolymer of a water soluble blend of water soluble ethylenically unsaturated monomer blends comprising carboxylic and hydroxylic monomers. The crosslinking is generally effected by irradiation or heating the polymer to a temperature of above 150° C.
EP-A-0357474 discloses a fabric impregnated with a formulation which crosslinks in situ on heating to form an absorbent polymer.
U.S. Pat. No. 4,017,653 discloses water swellable absorbent articles which are coated with a dry water swellable polyelectrolyte formed by coating the article with a solution of a carboxylic synthetic polyelectrolyte and a covalent crosslinking agent, and heating the coated article to crosslink the polyelectrolyte. The absorbent articles are generally coated fibrous substrates which can be used in forming diapers, tampons, meat trays or bath mats. Also disclosed are free standing films of the water swellable polyelectrolyte.
EP-A-0702031 discloses an aqueous composition of an absorbent polymer for use in preparing superabsorbent materials such as superabsorbent cellulosic fibers and superabsorbent nonwoven webs. The aqueous polymer composition comprises 20-90% of an &agr;, &bgr;- ethylenically unsaturated carboxylic acid monomer and at least one softening monomer, the aqueous composition being adjusted to pH 4-6 with an alkali metal hydroxide or an alkaline earth metal hydroxide and containing a divalent or trivalent metal cross-linking compound.
We have now developed a process for the preparation of nonwoven water blocking tapes for use in the manufacture of cables which does not involve the use of particulate water swellable materials, the use of thermoplastic binder resins or the use of covalent crosslinking agents which may be toxic and difficult to handle, or which produce toxic by-products during use.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a process for the manufacture of a nonwoven water blocking tape for use in cable manufacture, which process comprises the steps of:
(i) forming a coating of an aqueous solution of a water soluble polymer containing anionic groups and a multivalent ionic crosslinking agent on at least one surface of a nonwoven substrate material; and
(ii) drying and/or curing the said coating in order to form a partially crosslinked water swellable polymer coating on the said at least one surface of the nonwoven substrate material.
In another aspect the present invention provides a water blocking tape which comprises a nonwoven substrate material as above defined having a coating on at least one surface thereof of a water soluble polymer containing anionic groups which is partially crosslinked with a multivalent ionic crosslinking agent.
DETAILED DESCRIPTION OF THE INVENTION
Nonwoven substrate materials which can be coated in accordance with the present invention include those which are formed from fibers of natural cellulose materials, such as woodpulp, cotton and hemp; synthetic cellulose fibers, such as rayon; regenerated cellulose fibers; synthetic fibers such as polyamide, nylon, polyester, acrylic or polyolefin fibers. The fibers may be used alone or in combination with one another.
Techniques for forming nonwoven substrate materials are known and the starting fibers can be formed by any one of the conventional techniques including carding, air-laying, wet-laying etc. Generally, the fibers will extend in a plurality of diverse d
Fairgrieve Stuart P.
Gruhn Joel David
Shows Phillip Douglas
Watts Jennifer Clare
Allen Marianne P.
Mintz Levin Cohn Ferris Glovsky and Popeo P.C.
Neptco, Inc.
Zeman M. K.
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