Coated substrates and optical fibers formed therefrom

Abstract

Embodiments of the present disclosure are directed to a coated substrate comprising a water swellable coating applied to the substrate. Based on the total weight of the water-swellable coating, the water-swellable coating comprises 30% to 90% by weight of a plastisol binder and 10% to 70% by weight of a superabsorbent polymer. The plastisol binder comprises from 1 wt% to 50 wt% of a water soluble polymer and from 50 wt% to 99 wt% of a plasticizer, based on the total weight of the plastisol binder.

Description

[0001] Claim priority

[0002] This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 63 / 436,094, filed December 29, 2022, with attorney docket number 1202225, which is incorporated herein by reference in its entirety. Technical Field

[0003]

[0014] Embodiments of the present disclosure generally relate to a coated substrate having a water-swellable coating thereon that possesses advantageous water absorption capabilities. Background Art

[0004] Water-swellable substrates, such as yarns and ribbons, are used in outdoor or water-sensitive cable applications to prevent water ingress. Traditional water-swellable substrates are made of superabsorbent polymers bonded to yarns with either water-insoluble or water-soluble binders. However, water-insoluble binders may sequester some of the superabsorbent polymer and may slowly absorb incoming water, which may reduce the water-blocking efficiency of the yarn. While water-soluble binders may absorb incoming water faster than water-insoluble binders, water-soluble binders may dissolve slowly and expose the superabsorbent polymer to water, and may not offer any significant advantages over their insoluble counterparts.

[0005] Therefore, there is a continuing need for improved water-swellable substrates having increased water absorption capacity and improved resistance to water ingress for the aforementioned applications. Summary of the Invention

[0006]

[0014] Embodiments of the present disclosure are directed to coated substrates that include a water-swellable coating comprising a plastisol binder and a superabsorbent polymer.

[0007] According to one embodiment, a coated substrate is provided. The coated substrate includes a water-swellable coating applied to the substrate. The water-swellable coating comprises 30 to 90 wt% of a plastisol binder and 10 to 70 wt% of a superabsorbent polymer, based on the total weight of the water-swellable coating. The plastisol binder comprises 1 to 50 wt% of a water-soluble polymer and 50 to 99 wt% of a plasticizer, based on the total weight of the plastisol binder.

[0008] Other features and advantages of the embodiments described herein will be given in the detailed description below. For those skilled in the art, some of the features and advantages can be easily understood through these descriptions, or recognized by practicing the embodiments described herein, including the following specific embodiments and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic cross-sectional view of a coated substrate according to one or more embodiments described herein;

[0010] Figure 2 is a perspective view of a cable according to one or more embodiments described herein;

[0011] Figure 3 is a schematic cross-sectional view of another cable according to one or more embodiments described herein;

[0012] Figure 4 is a schematic cross-sectional view of another cable according to one or more embodiments described herein; and

[0013] Figure 5 is a schematic cross-sectional view of another cable according to one or more embodiments described herein. DETAILED DESCRIPTION

[0014] Reference will now be made in detail to various embodiments of coated substrates, particularly coated substrates including a water-swellable coating. The water-swellable coating comprises 30% to 90% by weight of a plastisol binder and 10% to 70% by weight of a superabsorbent polymer, based on the total weight of the water-swellable coating. The plastisol binder comprises 1% to 50% by weight of a water-soluble polymer and 50% to 99% by weight of a plasticizer, based on the total weight of the plastisol binder. In some embodiments, the coated substrate can have advantageous water absorption capabilities. The water-swellable coating can be used in the coating to provide advantageous resistance to water ingress.

[0015] The present disclosure should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided to make this disclosure thorough and complete and to fully convey the subject matter to those skilled in the art.

[0016] definition

[0017] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this disclosure is for describing particular embodiments only and is not intended to be limiting.

[0018] Approximate language, as used throughout the specification and claims, is used to modify any quantitative representation that can be permissibly varied without resulting in a change in the basic function to which it is related. Thus, a value modified by one or more terms such as "about," "approximately," and "substantially" is not limited to the precise value specified. In at least some cases, approximate language can correspond to the precision of an instrument used to measure the value, or the precision of a method or machine used to construct or manufacture a component and / or system. For example, approximate language can mean within a range of 10%.

[0019] Unless expressly stated otherwise, no method described herein should be construed as requiring that its steps be performed in a particular order, nor should any apparatus be construed as requiring a particular orientation. Therefore, in the absence of a method claim that actually recites the order in which its steps are to be followed, or an apparatus claim that actually recites the order or orientation of its components, or in the absence of other explicit statements in the claims or specification that the steps are to be limited to a particular order, or in the absence of a specific order or orientation of apparatus components, no order or orientation should be inferred in any respect. This applies to any possible non-explicit basis for expression, including: logical issues involving the arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.

[0020] As used in the description of the embodiments and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" component includes aspects having two or more such components unless the context clearly dictates otherwise.

[0021] Unless otherwise indicated, the term "wt %" as used herein refers to the weight fraction of an individual component based on the total weight of the water-swellable coating or plastisol binder.

[0022] As used herein, the terms "water-soluble," "dissolvable," or "soluble" mean that at least 1 gram of the material can be dissolved per 30 grams of deionized water at standard temperature (20° C.) and pressure (1 atm) as visually observed.

[0023] As used herein, the term "plastisol" refers to a formulation comprising polymer particles suspended in a liquid plasticizer. When heated sufficiently, the polymer particles absorb the plasticizer, causing the polymer particles to fuse together to form a gel, thereby producing a permanently plasticized solid product.

[0024] As used herein, the term "plasticizer" refers to a molecule or substance added to a composition to promote plasticity and flexibility of the composition.

[0025] As used herein, the term "gelation temperature" refers to the temperature at which the peak viscosity is measured using a BASF Rheodynamic Analyzer (RDA).

[0026] As used herein, the term "water absorption capacity" refers to the amount of water that a solid material can absorb and can be expressed as the mass of water absorbed per unit mass of the solid material. For example, the water absorption capacity of a solid material can be expressed as the number of grams of distilled water absorbed per gram of solid material (e.g., g / g). To measure the water absorption capacity, a specified mass of absorbent material is obtained and 100 grams of water is added to the absorbent material. The material is stirred in the water for two minutes to break up any lumps. The absorbent material is allowed to stand in the water for an additional ten minutes. The expanded absorbent material is poured into a funnel lined with a paper coffee filter and the excess water is drained into a container. After fifteen minutes, the mass of the excess water is measured. The water absorption capacity is calculated by subtracting the mass of the excess water from the 100 grams of water. The resulting amount of water is then divided by the specified mass of the absorbent material.

[0027] As used herein, the term "plastisol binder," "plastisol," or "binder" refers to a formulation comprising a water-soluble polymer suspended in a plasticizer. Plastisol formulations may contain other ingredients and are contemplated in this disclosure.

[0028] As used herein, the term "initial water ingress" refers to the penetration of water into a coated substrate after 1 minute, as measured according to IEC 60794-1-22 Method 5FB, without pre-soaking.

[0029] As used herein, the terms "water ingress after 24 hours" and "24 hour water ingress" refer to the measurement of water ingress into a coated substrate after 24 hours, as tested according to IEC 60794-1-22 Method 5FB without pre-soaking.

[0030] As used herein, the term "dry cable" refers to the use of superabsorbent polymers to absorb and block water from entering the cable. The optical fiber is not contaminated by gels or other compounds, so labor-intensive cleaning is not required. The term "dry cable" distinguishes this design from traditional filled cables, which rely on water-blocking compounds or gels to prevent water ingress.

[0031] As used herein, the term "coating weight" refers to the amount of water-swellable coating applied to a given substrate based on the total weight of the coated substrate.

[0032] As described herein, water-swellable substrates (such as yarns) are used in outdoor or water-sensitive cable applications to prevent water ingress. Conventional water-swellable substrates are made of superabsorbent polymers that are bonded to the yarn by either a water-insoluble or water-soluble binder. However, the water-insoluble binder may sequester some of the superabsorbent polymer and may slowly absorb incoming water, which may reduce the water-blocking efficiency of the yarn. While a water-soluble binder may absorb incoming water faster than a water-insoluble binder, the water-soluble binder may dissolve slowly and expose the superabsorbent polymer to water and may not provide any significant advantages over its insoluble counterpart.

[0033] Disclosed herein are coated substrates that alleviate one or more of the aforementioned problems. Specifically, the coated substrates disclosed herein include a water-swellable coating applied to the substrate. The water-swellable coating comprises a plastisol binder and a superabsorbent polymer. The plastisol binder comprises a water-soluble polymer that rapidly dissolves in water, exposing the superabsorbent polymer to absorb water. The dissolved water-soluble polymer increases the viscosity of incoming water, further improving water-blocking efficiency.

[0034] Water-swellable coating

[0035] The water-swellable coatings disclosed herein can generally be described as comprising a superabsorbent polymer (SAP) and a plastisol binder.

[0036] Superabsorbent polymers

[0037] Typically, SAP is a water-absorbing, hydrophilic compound that can absorb and retain significant amounts of liquid relative to its mass. SAP can be used to block water penetration in applications such as underground power or communication cables, self-sealing concrete, horticultural water retention agents, and to control spills and wastewater fluids.

[0038] Without being bound by theory, SAPs are typically prepared from polymers that have ions along one or more chains in the polymer structure. Consequently, water enters the selected SAP to solvate the ionic groups, which in turn may result in a higher osmotic pressure. This may result in a higher water absorption capacity because water swells the polymer network to maintain a balance of ion concentrations between the polymer and the water. In some embodiments, the SAP may include a polyacrylate-based polymer salt, a polyacrylamide-based polymer salt, or a combination thereof. In some embodiments, the polyacrylate-based polymer salt includes a sodium polyacrylate-based polymer, a potassium polyacrylate-based polymer, an ammonium acrylate-based polymer, or a combination thereof.

[0039] The water-swellable coating may contain a minimum amount of SAP (e.g., greater than or equal to 10 wt %) to ensure the desired water absorption capacity is achieved. The amount of SAP in the water-swellable coating may be minimized (e.g., less than or equal to 70 wt %) to ensure that the water-swellable coating exhibits liquid properties. Thus, in some embodiments, the water-swellable coating may contain 10 wt % to 70 wt % SAP, based on the total weight of the water-swellable coating. In some embodiments, the amount of SAP in the water-swellable coating may be greater than or equal to 10 wt %, greater than or equal to 15 wt %, greater than or equal to 20 wt %, greater than or equal to 25 wt %, or greater than or equal to 30 wt %, based on the total weight of the water-swellable coating. In some embodiments, the amount of SAP in the water-swellable coating may be less than or equal to 70 wt %, less than or equal to 65 wt %, less than or equal to 60 wt %, less than or equal to 55 wt %, less than or equal to 50 wt %, less than or equal to 45 wt %, less than or equal to 40 wt %, or even less than or equal to 35 wt %, based on the total weight of the water-swellable coating. In some embodiments, the amount of SAP in the water-swellable coating may be 10 wt % to 70 wt %, 10 wt % to 65 wt %, 10 wt % to 60 wt %, 10 wt % to 55 wt %, 10 wt % to 50 wt %, 10 wt % to 45 wt %, 10 wt % to 40 wt %, 10 wt % to 35 wt %, 15 wt % to 70 wt %, 15 wt % to 65 wt %, 15 wt % to 60 wt %, 15 wt % to 55 wt %, 15 wt % to 50 wt %, 15 wt % to 45 wt %, 15 wt % to 40 wt %, 15 wt % to 35 wt %, 20 wt % to 70 wt %, 20 wt % to 65 wt %, 20 wt % to 60 wt %, 20 wt % to % to 55 wt%, 20 wt% to 50 wt%, 20 wt% to 45 wt%, 20 wt% to 40 wt%, 20 wt% to 35 wt%, 25 wt% to 70 wt%, 25 wt% to 65 wt%, 25 wt% to 60 wt%, 25 wt% to 55 wt%, 25 wt% to 50 wt%, 25 wt% to 45 wt%, 25 wt% to 40 wt%, 25 wt% to 35 wt%, 30 wt% to 70 wt%, 30 wt% to 65 wt%, 30 wt% to 60 wt%, 30 wt% to 55 wt%, 30 wt% to 50 wt%, 30 wt% to 45 wt%, 30 wt% to 40 wt%, or even 30 wt% to 35 wt%, or any and all subranges formed by any of these endpoints.

[0040] In some embodiments, the water absorption capacity of the SAP may be between 10 g / g and 1000 g / g. In some embodiments, the water absorption capacity of the SAP may be greater than or equal to 10 g / g, greater than or equal to 50 g / g, greater than or equal to 100 g / g, greater than or equal to 150 g / g, greater than or equal to 200 g / g, greater than or equal to 250 g / g, greater than or equal to 300 g / g, or even greater than or equal to 350 g / g. In some embodiments, the water absorption capacity of the SAP may be less than or equal to 1000 g / g, less than or equal to 950 g / g, less than or equal to 900 g / g, less than or equal to 850 g / g, less than or equal to 800 g / g, less than or equal to 750 g / g, less than or equal to 700 g / g, less than or equal to 650 g / g, less than or equal to 600 g / g, less than or equal to 550 g / g, or even less than or equal to 500 g / g. In some embodiments, the water absorption capacity of the SAP can be 10 g / g to 1000 g / g, 10 g / g to 950 g / g, 10 g / g to 900 g / g, 10 g / g to 850 g / g, 10 g / g to 800 g / g, 10 g / g to 750 g / g, 10 g / g to 700 g / g, 10 g / g to 650 g / g, 10 g / g to 600 g / g, 10 g / g to 550 g / g, 10 g / g to 500 g / g. , 100 g / g to 1000 g / g, 100 g / g to 950 g / g, 100 g / g to 900 g / g, 100 g / g to 850 g / g, 100 g / g to 800 g / g, 100 g / g to 750 g / g, 100 g / g to 700 g / g, 100 g / g to 650 g / g, 100 g / g to 600 g / g, 100 g / g to 550 g / g, 100 g / g to 500 g / g, 200 g / g to 1000 g / g, 200 g / g to 950 g / g, 200 g / g to 900 g / g, 200 g / g to 850 g / g, 200 g / g to 800 g / g, 200 g / g to 750 g / g, 200 g / g to 700 g / g, 200 g / g to 650 g / g, 200 g / g to 600 g / g, 200 g / g to 550 g / g, 200 g / g to 500 g / g, 350 g / g to 1000 g / g, g / g, 350 g / g to 950 g / g, 350 g / g to 900 g / g, 350 g / g to 850 g / g, 350 g / g to 800 g / g, 350 g / g to 750 g / g, 350 g / g to 700 g / g, 350 g / g to 650 g / g, 350 g / g to 600 g / g, 350 g / g to 550 g / g, or even 350 g / g to 500 g / g, or any and all subranges formed by any of these endpoints.

[0041] In some embodiments, the SAP contained in the water-swellable coating can include SAP powder. In these or other embodiments, the water-swellable coating can include SAP powder particles dispersed in the water-swellable coating.

[0042] Suitable commercial embodiments of water-soluble polymer particles are available from Stewart Superabsorbites, for example, sodium polyacrylate polymer MAX 400-53; and Sumitomo Seika, for example, sodium polyacrylate polymer AQUAKEEP 10SF SAP.

[0043] Plastisol binder

[0044] In some embodiments, the water-swellable coating may comprise 30% to 90% by weight of the plastisol binder, based on the total weight of the water-swellable coating. In some embodiments, the amount of plastisol binder in the water-swellable coating may be greater than or equal to 30% by weight, greater than or equal to 35% by weight, greater than or equal to 40% by weight, greater than or equal to 45% by weight, greater than or equal to 50% by weight, greater than or equal to 55% by weight, greater than or equal to 60% by weight, or even greater than or equal to 65% by weight, based on the total weight of the water-swellable coating. In some embodiments, the amount of plastisol binder in the water-swellable coating may be less than or equal to 90% by weight, less than or equal to 85% by weight, less than or equal to 80% by weight, less than or equal to 75% by weight, or less than or equal to 70% by weight, based on the total weight of the water-swellable coating. In some embodiments, the amount of plastisol binder in the water-swellable coating may be 30 wt % to 90 wt %, 30 wt % to 85 wt %, 30 wt % to 80 wt %, 30 wt % to 75 wt %, 30 wt % to 70 wt %, 35 wt % to 90 wt %, 35 wt % to 85 wt %, 35 wt % to 80 wt %, 35 wt % to 75 wt %, 35 wt % to 70 wt %, 40 wt % to 90 wt %, 40 wt % to 85 wt %, 40 wt % to 80 wt %, 40 wt % to 75 wt %, 40 wt % to 70 wt %, 45 wt % to 90 wt %, 45 wt % to 85 wt %, 45 wt % to 80 wt %, 45 wt % to 75 wt %, 45 % to 70 wt%, 50 wt% to 90 wt%, 50 wt% to 85 wt%, 50 wt% to 80 wt%, 50 wt% to 75 wt%, 50 wt% to 70 wt%, 55 wt% to 90 wt%, 55 wt% to 85 wt%, 55 wt% to 80 wt%, 55 wt% to 75 wt%, 55 wt% to 70 wt%, 60 wt% to 90 wt%, 60 wt% to 85 wt%, 60 wt% to 80 wt%, 60 wt% to 75 wt%, 60 wt% to 70 wt%, 65 wt% to 90 wt%, 65 wt% to 85 wt%, 65 wt% to 80 wt%, 65 wt% to 75 wt%, or even 65 wt% to 70 wt%, or any and all subranges formed by any of these endpoints.

[0045] The plastisol binders disclosed herein include a water-soluble polymer and a plasticizer. When certain water-soluble polymers and plasticizers are combined and heated to their gelation temperatures, as described below, the resulting plastisol binder may solidify into a non-flowable but semi-flexible mass upon cooling.

[0046] Water-soluble polymers

[0047] The water-soluble polymer provides the resulting plastisol binder with the ability to dissolve, disperse, or swell in water. In some embodiments, the water-soluble polymer particles included in the plastisol binders disclosed herein may include natural or synthetic polymers.

[0048] In some embodiments, the water-soluble polymer can be selected from the group consisting of polysaccharides, polypeptides, and combinations thereof. In one embodiment, the water-soluble polymer can include hydroxypropyl methylcellulose (HPMC). Water-soluble polymers selected from this group may be ideal in food or medical grade applications.

[0049] In other embodiments, the water-soluble polymer may include a synthetic water-soluble polymer. In some other embodiments, the water-soluble polymer may be selected from the group consisting of polyvinyl alcohol, polyacrylic acid copolymer, poly(2-ethyl-2-oxazoline), polyvinyl pyrrolidone, and combinations thereof.

[0050] The dissolving power of the water-soluble polymer particles may be affected by the pH level of the liquid (e.g., water) used to dissolve the plasticized film or article. For example, some water-soluble polymers may have relatively poor solubility under neutral or acidic conditions. The liquid plastisol compositions disclosed herein can be adjusted to take into account the pH level of the dissolving liquid. In some embodiments, a buffer can be used in the liquid plastisol composition to provide a suitable pH level to dissolve the water-soluble polymer of the plasticized film or article in water. In some embodiments, an acid can be used in the liquid plastisol composition to provide a suitable pH level to dissolve the water-soluble polymer of the plasticized film or article in water. In some embodiments, a base can be used in the liquid plastisol composition to provide a suitable pH level to dissolve the water-soluble polymer of the plasticized film or article in water.

[0051] The plastisol binder may contain a minimum amount of water-soluble polymer (e.g., greater than or equal to 1 wt %) to ensure that the desired shape (e.g., coating) of the article is achieved upon cooling. The amount of water-soluble polymer in the plastisol binder may be limited (e.g., less than or equal to 50 wt %) to achieve the desired viscosity for processing purposes (e.g., coating a substrate). Thus, in some embodiments, the amount of water-soluble polymer in the plastisol binder may be from 1 wt % to 50 wt %, based on the total weight of the plastisol binder. In some embodiments, the amount of water-soluble polymer in the plastisol binder may be greater than or equal to 1 wt % or even greater than or equal to 5 wt %, based on the total weight of the plastisol binder. In some embodiments, the amount of water-soluble polymer in the plastisol binder may be less than or equal to 50 wt %, less than or equal to 40 wt %, less than or equal to 30 wt %, less than or equal to 20 wt %, or even less than or equal to 10 wt %, based on the total weight of the plastisol binder. In some embodiments, the amount of water-soluble polymer in the plastisol binder can be 1 wt % to 50 wt %, 1 wt % to 40 wt %, 1 wt % to 30 wt %, 1 wt % to 20 wt %, 1 wt % to 10 wt %, 5 wt % to 50 wt %, 5 wt % to 40 wt %, 5 wt % to 30 wt %, 5 wt % to 20 wt %, or even 5 wt % to 10 wt %, based on the total weight of the plastisol binder, or any and all subranges derived from any of these endpoints.

[0052] Water-soluble polymer particles with a smaller average particle size can be used to ensure that the water-soluble polymer particles are formed into an article or film, wherein the water-soluble polymer particles have completely absorbed the plasticizer to form a consistent gel. In some embodiments, the water-soluble polymer can be provided in powder form. In some embodiments, the water-soluble polymer can be ground to produce the desired average particle size. In some embodiments, the water-soluble polymer can have a minimum average particle size (e.g., greater than or equal to 1 micron) to ensure that the water-soluble polymer does not clump and is not too fine to handle. The average particle size of the water-soluble polymer can be limited (e.g., less than or equal to 500 microns) to ensure that the water-soluble polymer can be completely soaked and gelled to form a consistent coating. Therefore, in some embodiments, the average particle size of the water-soluble polymer in the plastisol binder can be between 1 micron and 500 microns. In some embodiments, the average particle size of the water-soluble polymer particles in the plastisol binder can be greater than or equal to 1 micron, greater than or equal to 50 microns, or even greater than or equal to 100 microns. In some embodiments, the average particle size of the water-soluble polymer in the plastisol binder can be less than or equal to 500 microns, less than or equal to 450 microns, less than or equal to 400 microns, less than or equal to 350 microns, less than or equal to 300 microns, or even less than or equal to 250 microns. In some embodiments, the average particle size of the water-soluble polymer in the plastisol binder can be 1 micron to 500 microns, 1 micron to 450 microns, 1 micron to 400 microns, 1 micron to 350 microns, 1 micron to 300 microns, 1 micron to 250 microns, 50 microns to 500 microns, 50 microns to 450 microns, 50 microns to 400 microns, 50 microns to 350 microns, 50 microns to 300 microns, 50 microns to 250 microns, 100 microns to 500 microns, 100 microns to 450 microns, 100 microns to 400 microns, 100 microns to 350 microns, 100 microns to 300 microns, 100 microns to 250 microns, or any or all subranges formed from any of these endpoints.

[0053] Suitable commercial embodiments of water-soluble polymers are available from Kuraray under the POVAL brand, such as polyvinyl alcohol 49-88 S2 grade, and DuPont under the METHOCEL brand.

[0054] plasticizers

[0055] Suitable plasticizers for the liquid plastisol compositions of the present disclosure include those that form a liquid dispersion or slurry when combined with the water-soluble polymer particles. Upon sufficient heating, the water-soluble polymer particles in the liquid plastisol composition absorb the plasticizer, causing the water-soluble polymer particles to swell and fuse together to form a gel. The resulting product is a permanently plasticized solid product.

[0056] In some embodiments, the plasticizer may include a polyol. In some embodiments, the polyol may be a diol. In other embodiments, the polyol may be a triol. In other embodiments, the polyol may include 4, 5, or more than 6 hydroxyl groups. In some embodiments, a polyol exhibiting a polarity similar to that of the selected water-soluble polymer particles may be selected. Plasticizers selected from this group may also be advantageous in applications involving short-life applications (such as food packaging). In some embodiments, the plasticizer may be selected from the group consisting of: diols, sugar alcohols, sugars, glycerol, triacetin, propylene carbonate, fatty acids, urea, and combinations thereof. Exemplary diols include propylene glycol and polyethylene glycol ("PEG"). Suitable polyethylene glycols should be liquid at 22°C (e.g., PEGs having a MW of 600 g / mol or less). In some embodiments, the MW of the polyethylene glycol may be from 100 g / mol to 600 g / mol, from 200 g / mol to 550 g / mol, or from 300 g / mol to 500 g / mol.

[0057] In some embodiments, a minimal amount of plasticizer (e.g., greater than or equal to 50% by weight) may be included in the plastisol binder to ensure the liquid nature of the binder. The amount of plasticizer in the liquid plastic binder may be limited (e.g., less than or equal to 97% by weight) to ensure a consistent coating. Thus, in some embodiments, the plastisol binder may include 50% to 99% by weight of plasticizer based on the total weight of the plastisol binder. In some embodiments, the amount of plasticizer in the plastisol binder may be greater than or equal to 50 wt %, greater than or equal to 55 wt %, greater than or equal to 60 wt %, greater than or equal to 65 wt %, greater than or equal to 70 wt %, greater than or equal to 75 wt %, greater than or equal to 80 wt %, greater than or equal to 85 wt %, or even greater than or equal to 90 wt %, based on the total weight of the plastisol binder. In some embodiments, the amount of plasticizer in the plastisol binder may be less than or equal to 99 wt %, less than or equal to 95 wt %, less than or equal to 90 wt %, less than or equal to 85 wt %, less than or equal to 80 wt %, less than or equal to 75 wt %, or even less than or equal to 70 wt %, based on the total weight of the plastisol binder.In some embodiments, the amount of plasticizer in the plastisol binder can be 50% to 99% by weight, 50% to 95% by weight, 50% to 90% by weight, 50% to 85% by weight, 50% to 80% by weight, 50% to 75% by weight, 50% to 70% by weight, 55% to 99% by weight, 55% to 95% by weight, 55% to 90% by weight, 55% to 85% by weight, 55% to 80% by weight, 55% to 75% by weight, 55% to 70% by weight, 60% to 99% by weight, 60% to 95% by weight, 60% to 90% by weight, 60% to 85% by weight, 60% to 80% by weight, 60% to 75% by weight, 60% to 70% by weight, 65% to 99% by weight, 65% to 95% by weight, 65% to 80% by weight, % to 90% by weight, 65% to 85% by weight, 65% to 80% by weight, 65% to 75% by weight, 65% to 70% by weight, 70% to 99% by weight, 70% to 95% by weight, 70% to 90% by weight, 70% to 85% by weight, 70% to 80% by weight, 70% to 75% by weight, 75% to 99% by weight, 75% to 95% by weight, 75% to 90% by weight, 75% to 85% by weight, 75% to 80% by weight, 80% to 99% by weight, 80% to 95% by weight, 80% to 90% by weight, 80% to 85% by weight, 85% to 99% by weight, 85% to 95% by weight, 85% to 90% by weight, 90% to 99% by weight, or even 90% to 95% by weight, or any and all subranges formed by any of these endpoints.

[0058] Suitable commercial embodiments of plasticizers are available from Nature's Oil, such as USP grade propylene glycol.

[0059] additive

[0060] The plastisol binder may further comprise additives selected from the group consisting of viscosity modifiers, viscosity stabilizers, heat stabilizers, UV stabilizers, dyes, pigments, preservatives, fillers, adhesion promoters, lubricants, and combinations thereof. These additives may be selected based on their ability to be customized to improve specific aspects of the water-swellable coating, thereby facilitating processing, enhancing performance, or extending service life.

[0061] In some embodiments, the amount of additives in the plastisol binder can be 1 wt % to 20 wt % based on the total weight of the plastisol binder. In some embodiments, the amount of additives in the plastisol binder can be greater than or equal to 1 wt %, greater than or equal to 3 wt %, or even greater than or equal to 5 wt %, based on the total weight of the plastisol binder. In some embodiments, the amount of additives in the plastisol binder can be less than or equal to 20 wt %, less than or equal to 15 wt %, or even less than or equal to 10 wt %, based on the total weight of the plastisol binder. In some embodiments, the amount of additives in the plastisol binder can be 1 wt % to 20 wt %, 1 wt % to 15 wt %, 1 wt % to 10 wt %, 3 wt % to 20 wt %, 3 wt % to 15 wt %, 3 wt % to 10 wt %, 5 wt % to 20 wt %, 5 wt % to 15 wt %, or even 5 wt % to 10 wt %, or any and all subranges formed from any of these endpoints, based on the total weight of the plastisol binder.

[0062] Advantageously, the plastisol binder can be prepared without water. In some embodiments, the plastisol binder can be substantially free of water. In some embodiments, the plastisol binder can have less than 5 wt%, less than 3 wt%, less than 1 wt%, less than 0.5 wt%, or less than 0.1 wt% water based on the total weight of the plastisol binder.

[0063] substrate

[0064] In embodiments of the coated substrates of the present disclosure, the substrate can comprise yarn, fabric, textile, nonwoven, paper, sheet, mesh, or scrim. In some embodiments, the substrate can be composed of fibers of polyamide, aramid, or copolymers thereof, cellulose regenerated fibers, polyester, polyolefin, polyacrylic acid, polybenzoxazole, liquid crystal polymer, glass fiber, basalt, rock wool, ceramic, metal, carbon, plant-based fibers (e.g., cotton, hemp, jute), animal-based fibers (e.g., wool, silk), or combinations thereof.

[0065] In embodiments of the coated substrate disclosed herein, the substrate may include a continuous fiber reinforcement. Continuous fiber reinforcement, also referred to as a continuous fiber ribbon, comprises a matrix material and a plurality of unidirectional continuous fibers embedded in a thermoplastic matrix. Suitable fibers include glass fibers, aramid fibers, basalt fibers, carbon fibers, or combinations thereof. Suitable matrices include thermoplastic polymers or blends of two or more thermoplastic polymers.

[0066] Now refer to Figure 1, a coated substrate 100 is shown. The coated substrate 100 includes a water-swellable coating 102 as described herein applied to a substrate 104 as shown herein. The water-swellable coating 102 can be applied to the substrate 104 by screen printing, roller coating, spraying, slot die coating, dip molding, dipping, spin coating, rotational molding, slush casting, injection molding, or extrusion. When applied, the water-swellable coating 102 can be in the form of a slurry, as described below.

[0067] After application, the coated substrate 100 can be heated to a gelation temperature to convert the water-swellable coating 102 from a slurry to a gelled plastisol. In some embodiments, the gelation temperature can be 90° C. to 170° C., 90° C. to 155° C., 90° C. to 140° C., 105° C. to 170° C., 105° C. to 155° C., 105° C. to 140° C., 120° C. to 170° C., 120° C. to 155° C., or even 120° C. to 140° C. In some embodiments, the coated substrate 100 can be heated at the gelation temperature for a period of time to allow the gelled plastisol to adhere to the substrate. In some embodiments, the coated substrate 100 can then be cooled (e.g., to room temperature) to form the water-swellable coating 102.

[0068] The coated substrate 100 may have an improved water absorption capacity to prevent water from entering. In some embodiments, the water absorption capacity of the coated substrate 100 may be 5 g / g to 800 g / g. In some embodiments, the water absorption capacity of the coated substrate 100 may be greater than or equal to 5 g / g, greater than or equal to 50 g / g, greater than or equal to 100 g / g, greater than or equal to 150 g / g, greater than or equal to 200 g / g, greater than or equal to 250 g / g, greater than or equal to 300 g / g, greater than or equal to 350 g / g, greater than or equal to 400 g / g, or even greater than or equal to 450 g / g. In some embodiments, the water absorption capacity of the coated substrate 100 can be less than or equal to 800 g / g, less than or equal to 750 g / g, less than or equal to 700 g / g, less than or equal to 650 g / g, less than or equal to 600 g / g, less than or equal to 550 g / g, less than or equal to 500 g / g, or even less than or equal to 450 g / g. In some embodiments, the water absorption capacity of the coated substrate 100 can be from 5 g / g to 800 g / g, from 5 g / g to 750 g / g, from 5 g / g to 700 g / g, from 5 g / g to 650 g / g, from 5 g / g to 600 g / g, from 5 g / g to 550 g / g, from 5 g / g to 500 g / g, from 5 g / g to 450 g / g, from 5 g / g to 400 g / g, from 5 g / g to 350 g / g, from 5 g / g to 300 g / g. g / g, 100 g / g to 800 g / g, 100 g / g to 750 g / g, 100 g / g to 700 g / g, 100 g / g to 650 g / g, 100 g / g to 600 g / g, 100 g / g to 550 g / g, 100 g / g to 500 g / g, 100 g / g to 450 g / g, 100 g / g to 400 g / g, 100 g / g to 350 g / g, 100 g / g to 300 g / g, 200 g / g to 800 g / g, 200 g / g to 750 g / g, 200 g / g to 700 g / g, 200 g / g to 650 g / g, 200 g / g to 600 g / g, 200 g / g to 550 g / g, 200 g / g to 500 g / g, 200 g / g to 450 g / g, 200 g / g to 400 g / g, 200 g / g to 350 g / g, 200 g / g to 300 g / g, 350 g / g to 800 g / g, 350 g / g to 750 g / g, 350 g / g to 700 g / g, 350 g / g to 650 g / g, 350 g / g to 600 g / g, 350 g / g to 550 g / g, 350 g / g to 500 g / g, 350 g / g to 450 g / g, or even 350 g / g to 400 g / g, or any and all subranges formed by any of these endpoints.

[0069] The coated substrate 100 can be cut, converted, formed, or incorporated into other articles for various uses.

[0070] For example, now refer to Figure 2 , a cable 150 is shown, comprising a cable jacket 152 and a cable component 154 encased by the cable jacket 152. The cable component 154 may be a conductor, an optical fiber, a strength member, a rip cord, or a filler. The water-swellable coating described herein may be incorporated into the cable 150 in various ways, such that different portions of the cable 150 may be coated substrates.

[0071] For example, now refer to Figure 3 , a cable 200 is shown, comprising a cable jacket 202, a buffer tube 203, and a cable assembly 204 encased by the cable jacket 202 and buffer tube 203. In some embodiments, the buffer tube 203 may be a fiber optic buffer tube. In this embodiment, the buffer tube 203 is a coated substrate coated with a water-swellable coating 206. Therefore, if water enters the cable 200 through a crack or defect in the cable jacket 202 or buffer tube 203, the water-swellable coating 206 can absorb the water and swell, thereby preventing further water from entering the cable assembly 204.

[0072] In some embodiments, the optical fiber buffer tube has an initial water ingress less than that of a similar buffer tube, when tested according to IEC 60794-1-22 Method 5FB without pre-preg, and the similar buffer tube is identical except for including a PVC plastisol binder. For example, in some embodiments, the initial water ingress of the optical fiber buffer tube can be less than 40 cm or even less than or equal to 35 cm when tested according to IEC 60794-1-22 Method 5FB without pre-preg.

[0073] In some embodiments, when tested according to IEC 60794-1-22 Method 5FB without pre-soaking, the water ingress of the optical fiber buffer tube after 24 hours can be less than 100 cm, less than 85 cm, less than or equal to 70 cm, less than or equal to 55 cm, or less than or equal to 40 cm.

[0074] Those skilled in the art will appreciate that the amount of water ingress into an optical fiber buffer tube depends on various factors, such as the number of buffer tube layers and the amount of void space in the buffer tube.

[0075] In another example, now refer to Figure 4, a cable 300 is shown comprising a cable jacket 302 and cable components 304. In this embodiment, the cable components 304 are a coated substrate and are coated with a water-swellable coating 306. The cable components 304 can be collectively coated with the water-swellable coating 306 such that the water-swellable coating acts as a gel. The water-swellable coating 306 can be used to fill gaps within the cable jacket 302 and between the cable components 304. Alternatively, the cable components 304 can be individually coated with the water-swellable coating 306. Similar to Figure 3 In the illustrated embodiment, if water enters the cable 300 through a rupture or defect in the cable jacket 300 or the buffer tube 302 , the water-swellable coating 306 can absorb the water and swell, thereby preventing the water from further entering the cable assembly 304 .

[0076] In another example, now refer to Figure 5 , shows a cable 400 that includes a cable jacket 402 and a cable assembly 404. In this embodiment, called a "dry cable" design, the continuous filament yarn 406 is a coated substrate and is coated with a water-swellable coating. In some embodiments, the continuous filament yarn 406 can be woven or knitted to form a fabric; cut and reassembled into a non-woven textile; used as a binder, filler, or strength member in the cable 400. The continuous filament yarn 406 coated with the water-swellable coating can protect the cable assembly 404 from physical damage. In the event that the cable jacket 402 is damaged and water enters the cable jacket 402, the continuous filament yarn 406 with the water-swellable coating absorbs the water and swells to fill the gaps within the cable 400. The now swollen continuous filament yarn 406 prevents further penetration of water.

[0077] Processing

[0078] In some embodiments, a method of preparing a water-swellable coating described herein may include blending a plastisol binder (including a water-soluble polymer and a plasticizer) with a SAP to form a slurry, and mixing until the slurry is homogeneous.

[0079] Example

[0080] Table 1 below shows the sources of the ingredients used to form Examples E1 to E4.

[0081] Table 1

[0082]

[0083] The formulations used to form water-swellable coating Examples E1-E3 are shown below in Table 2. Table 2 also lists the coating weight and water absorption capacity of the coated substrate in grams of water per gram of coated substrate.

[0084] Table 2

[0085]

[0086] To form Example E1, a mixture of AQUAKEEP 10SF-SAP (SAP), USP grade propylene glycol (plasticizer), and POVAL 49-88S2 (water-soluble polymer) was prepared in a mixer. The mixture was spread between two layers of XPECT (substrate) and placed in a hot press at 140°C for 30 seconds. The coated XPECT was removed from the hot press and cooled to room temperature. The water absorption capacity of the coated XPECT was 92 grams of water per gram of coated substrate.

[0087] To form Example E2, a mixture of AQUAKEEP 10SF-SAP (SAP), USP-grade propylene glycol (plasticizer), and POVAL 49-88S2 (water-soluble polymer) was prepared in a mixer. 1000 denier para-aramid yarn KEVLAR (substrate) was coated with this mixture and placed in an oven heated to 180°C for 40 seconds. The coated KEVLAR was then removed from the oven and cooled to room temperature. The coated KEVLAR had a water absorption capacity of 7 grams of water per gram of coated substrate.

[0088] To form Example E3, a mixture consisting of AQUAKEEP 10SF-SAP (SAP), USP grade propylene glycol (plasticizer), and POVAL 49-88S2 (water-soluble polymer) was prepared in a mixer. The mixture was spread between two layers of XPECT (substrate) and placed in a hot press at 140°C for 30 seconds. The coated XPECT was removed from the hot press and cooled to room temperature. The water absorption capacity of the coated XPECT was 28 grams of water per gram of coated substrate.

[0089] As shown in Examples E1-E3 in Table 2, the water-swellable coatings described herein can be used to form coated substrates with increased water absorption capacity.

[0090] Table 3 below shows the formulation used to form the water-swellable coating Example E4. Table 3 also lists the coating weight, the water absorption capacity of the coated substrate in grams of water per gram of coated substrate, the initial water uptake of the coated substrate, and the 24-hour water uptake.

[0091] Table 3

[0092]

[0093] To form Example E4, DIOLEN (substrate) was coated with the water-swellable coating shown in Table 3. To apply the coating, the DIOLEN was passed through a bath, excess coating was wiped off with a die, and the coated DIOLEN was then passed through an oven. The temperature and speed of the DIOLEN were adjusted until the coating was properly fused. The resulting water absorption capacity of one end (i.e., a strand) of the coated DIOLEN was 68 grams of water per gram of coated substrate, with an initial water intake of 33.7 cm and a 24-hour water intake of 34.3 cm.

[0094] As shown in Example E4 in Table 3, a water-swellable coating comprising a superabsorbent polymer and a plastisol binder (comprising a water-soluble polymer and a plasticizer) can be used to coat a substrate to provide increased water absorption capacity and better resistance to water ingress.

[0095] Obviously, modifications and variations can be made without departing from the scope of the disclosure as defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

[0096] The claims are attached.

Claims

1. A coated substrate comprising: A water-swellable coating applied to a substrate, Wherein, based on the total weight of the water-swellable coating, the water-swellable coating comprises 30% to 90% by weight of a plastisol binder, based on the total weight of the plastisol binder, the plastisol binder comprising: 1 to 50 wt% of a water-soluble polymer; and 50% to 99% by weight plasticizer; and 10% to 70% by weight superabsorbent polymer.

2. The coated substrate of claim 1, wherein Substrates include yarn, fabric, textile, nonwoven, paper, sheet, web or scrim.

3. The coated substrate of claim 1, wherein Substrates include continuous fiber reinforcements, yarns, fabrics, textiles, nonwovens, papers, sheets, webs, or scrims.

4. The coated substrate of claim 1, wherein The substrate includes continuous fiber reinforcement.

5. The coated substrate of claim 1 or claim 2, wherein The substrate is composed of fibers of polyamide, aramid or copolymers thereof, cellulose regenerated fibers, polyester, polyolefin, polyacrylic acid, polybenzoxazole, liquid crystal polymer, glass fiber, basalt, rock wool, ceramic, metal, carbon, plant-based fibers, animal-based fibers or combinations thereof.

6. A coated substrate as claimed in any one of the preceding claims, wherein Superabsorbent polymer is superabsorbent polymer powder.

7. A coated substrate as claimed in any one of the preceding claims, wherein The water absorption capacity of superabsorbent polymers is from 10 g / g to 1000 g / g.

8. A coated substrate as claimed in any one of the preceding claims, wherein The superabsorbent polymer includes a salt of a polyacrylate-based polymer, a salt of a polyacrylamide-based polymer, or a combination thereof.

9. The coated substrate of claim 8, wherein The salt of the polyacrylate-based polymer includes a sodium polyacrylate-based polymer, a potassium polyacrylate-based polymer, an ammonium acrylate-based polymer, or a combination thereof.

10. A coated substrate as claimed in any one of the preceding claims, wherein The plastisol binder further comprises 1 to 20 wt % of additives based on the total weight of the plastisol binder.

11. The coated substrate of claim 10, wherein The additive is selected from the group consisting of viscosity modifiers, viscosity stabilizers, heat stabilizers, UV stabilizers, dyes, pigments, preservatives, fillers, adhesion promoters, lubricants, and combinations thereof.

12. A coated substrate as claimed in any one of the preceding claims, wherein The water-soluble polymer is selected from the group consisting of polyvinyl alcohol, polyacrylic acid copolymer, poly(2-ethyl-2-oxazoline), polyvinyl pyrrolidone, and combinations thereof.

13. The coated substrate of any one of claims 1 to 11, wherein The water-soluble polymer is selected from the group consisting of polysaccharides, polypeptides, and combinations thereof.

14. A coated substrate as claimed in any one of the preceding claims, wherein The plasticizer includes a polyol.

15. The coated substrate of any one of claims 1 to 13, wherein The plasticizer is selected from the group consisting of glycols, sugar alcohols, sugars, glycerol, triacetin, propylene carbonate, fatty acids, urea, and combinations thereof.

16. An optical fiber cable comprising: optical fiber; and Optical fiber buffer tube, wherein The optical fiber buffer tube comprises the coated substrate of any one of the preceding claims.

17. The optical fiber cable of claim 16, wherein: The optical fiber buffer tube has an initial water ingress less than that of similar buffer tubes, when tested according to IEC 60794-1-22 Method 5FB without pre-preg, and the similar buffer tubes are identical except for including a PVC plastisol binder.

18. The optical fiber cable of claim 16 or claim 17, wherein: When tested according to IEC 60794-1-22 Method 5FB without pre-soaking, the initial water ingress into the optical fiber buffer tube is less than 40 cm.

19. The fiber optic cable of claim 18, wherein When tested according to IEC 60794-1-22 Method 5FB without pre-soaking, the initial water ingress into the fiber buffer tube is less than 35 cm.

20. The optical fiber cable according to any one of claims 16 to 19, wherein When tested according to IEC 60794-1-22 Method 5FB without pre-soaking, the water ingress of the optical fiber buffer tube after 24 hours is less than 100 cm.

21. The fiber optic cable of claim 20, wherein When tested according to IEC 60794-1-22 Method 5FB without pre-soaking, the water ingress of the optical fiber buffer tube after 24 hours is less than 85 cm.

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