Optical fiber cable with compact binder less core

Abstract

The present disclosure provides an optical fiber cable (100) comprising a plurality of modules (102) comprising one or more optical fibers (104) A first module (102-1) of the plurality of modules 102 is physically coupled to at least a second module (102-2) by at least a bond member 106. Apparatus and method of manufacturing optical fiber cable (100) is also provided. The optical fiber cable (100) has reduced additional binding or strengthening components without compromised structural rigidity of the cable (100) or flexibility of the modules (102). Additionally, the optical fiber cable (100) is more economical to manufacture.

Description

[0001] OPTICAL FIBER CABLE WITH COMPACT BINDER LESS CORE

[0002] TECHNICAL FIELD

[0003] The present invention generally relates to the field of optical fiber cables. In particular, the present invention relates to an optical fiber cable comprising connected modules, an apparatus, and method for manufacturing thereof.

[0004] BACKGROUND OF THE INVENTION

[0005] This section is intended to provide information relating to the field of disclosure and thus, any approach or functionality described herein should not be assumed to qualify as prior art merely by its inclusion in this section.

[0006] With the rise of telecommunication and speed at which data needs to be transferred, the need for optical fiber cables have also increased. Efforts have been continuously made to decrease the diameter of the cables or pack more fibers within existing diameters of the optical fiber cables.

[0007] Conventional multi-tube optical fiber cables include multiple tubes, each tube containing one or more optical fibers. The tubes can be stranded in a helical manner and wound using one or more binder yarns to form a cable core, which is subsequently encapsulated within an outer sheath. Each tube is manufactured individually, and, in a second phase, multiple tubes are used as input to form the cable core, which is followed by sheathing phase to form the optical fiber cable.

[0008] Conventional optical fiber cables and mechanism for manufacturing the same has many limitations. One disadvantage is that binder yarns might damage the tubes, thus damaging or affecting performance of the encapsulated optical fibers. Another disadvantage is the increased requirement of material due to the use of binder yarns, and the consequent increase in overall optical fiber cable diameter and material cost of the optical fiber cable. Further, manufacturing of the optical fiber cable occurs in multiple phases, involving manufacturing of individual tubes followed by stranding and binding of the tubes and then sheathing them, which results in the manufacturing process requiring additional manufacturing lines and additional time.

[0009] There is therefore, a requirement in the art for an optical fiber cable and an apparatus of manufacturing thereof, that overcomes at least some of the disadvantages listed above.

[0010] SUMMARY OF THE PRESENT INVENTION In an aspect of the present invention, there is provided an optical fiber cable comprising a plurality of modules, said modules comprising one or more optical fibers, characterized in that a first module is physically coupled to at least a second module by at least a bond, wherein the material of the bond and the modules is the same.

[0011] In another aspect of the present invention, there is provided an apparatus for manufacturing a plurality of modules, comprising an extrusion module configured to house a die, wherein said die comprises a plurality of first slots arranged on a first plane of the die, wherein the plurality of first slots extend through the length of the die; and at least a second slot arranged on the first plane of the die, wherein the second slot is adapted to couple a first slot to at least a second slot, wherein the second slot extends through the length of the die, wherein the plurality of first slots are adapted to receive one or more optical fibers therethrough, and the plurality of first slots and second slots are adapted to receive a polymeric material to encapsulate the one or more optical fibers.

[0012] In an aspect of the present invention, there is provided a method of manufacturing an optical fiber cable, comprising: applying a polymeric material layer on at least an optical fiber through a plurality of slots of a die to obtain a plurality of modules, wherein a first module is physically coupled to at least a second module by a bond, wherein the material of the bond and the modules is the same, and wherein the bond is continuous with the module outer surface; and extruding a sheath to encapsulate the plurality of modules to obtain said optical fiber cable.

[0013] BRIEF DESCRIPTION OF THE ACCOMPANING DRAWINGS

[0014] The present disclosure, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the description, taken in connection with the accompanying drawings. These and other details of the present invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the scope of the present disclosure.

[0015] FIG. 1 A illustrates a schematic perspective view of an optical fiber cable, according to an embodiment of the present invention.

[0016] FIG. 1B-C illustrates schematic views of different arrangements of plurality of modules of the optical fiber cable of FIG. 1A, according to different embodiments of the invention.

[0017] FIG. 2A-B illustrates a schematic sectional view of a die for manufacturing the optical fiber cable of FIG. 1 A, according to an embodiment of the present invention.

[0018] DETAILED DESCRIPTION OF THE INVENTION In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of one or more embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter may each be used independently of one another or in any combination with other features. An individual feature may not address any of the problems discussed above or may address only some of the problems discussed above. Some of the problems discussed above may not be fully addressed by any of the features described herein. Example embodiments of the present disclosure are described below, as illustrated in various drawings, in which same reference numerals refer to the same parts throughout the different drawings.

[0019] The present invention provides an optical fiber cable comprising a plurality of modules, said modules comprising one or more optical fibers, characterized in that a first module is physically coupled to at least a second module by at least a bond, wherein the material of the bond and the modules is the same.

[0020] In an embodiment, at least a first module of the plurality of modules of the optical fiber cable comprises at least 6, at least 12, at least 24, at least 36, at least 48, or at least 96 optical fibers. In an embodiment, the number of optical fibers in each of the plurality of modules is the same. In an embodiment, the number of optical fibers in at least two of the plurality of modules is different. In an embodiment, the plurality of fibers in one or more of the plurality of the modules are loose fibers. In an embodiment, the plurality of fibers in one or more of the plurality of the modules are in the form of one or more ribbons. In an embodiment, the one or more ribbons can be intermittently bonded ribbons (IBRs), rollable ribbon, or flat ribbon. In an embodiment, the plurality of fibers in one or more of the plurality of the modules are stranded. In an embodiment, the stranding is in SZ manner. In an embodiment, the stranding is in one direction. In an embodiment, the plurality of optical fibers in one or more modules are unstranded.

[0021] In an embodiment, the optical fiber comprises a core and a cladding. In an embodiment, the optical fiber further comprises a sheath. In an embodiment, the sheath can be colored. In an embodiment, the diameter of the plurality of optical fibers in a module are the same. In an embodiment, the diameter of the plurality of optical fibers in the plurality of modules of the optical fiber cable is the same. In an embodiment, the diameter of the plurality of the optical fibers in a first module is a first diameter and the diameter of the plurality of the optical fibers in at least a second module is a second diameter. It is understood by a person skilled in the art that for the purposes of the present disclosure, the diameter of optical fiber is not a limiting or essential feature of the disclosure. The present disclosure encompasses optical fibers known in the art, which may conform to varying user requirements, such as, but not limited to, single mode fiber, multimode fiber and / or established standards, such as, but not limited to ITU-T standards.

[0022] In an embodiment, the optical fiber cable comprises at least 3 modules. In an embodiment, the optical fiber cable can comprise up to 24 modules. In another embodiment, the optical fiber cable can comprise up to 48 modules. In an embodiment, the plurality of modules are tubes. In an embodiment, the tubes are loose tubes. In an embodiment, the tubes are tight buffered tubes. In an embodiment, the tube is made of a material selected from the group consisting of halogen-free flame-retardant (HFFR) materials, polyester, polyurethane, polycarbonate, polyolefin, and polyvinyl chloride. In an embodiment the module can have a wall thickness in the range 0.05mm to 0.3mm. In another embodiment, the thickness of module wall may vary. In an embodiment, the wall thickness of the plurality of modules in the optical fiber cable is the same. In an embodiment, the wall thickness of at least a first module of plurality of modules in the optical fiber cable is different from at least a second module.

[0023] In an embodiment, at least a first module is physically coupled to at least a second module by at least a bond. In an embodiment, a first module is physical coupled to at least a second module by a single bond. In an embodiment, a first module is physically coupled to at least a second module by a plurality of bonds. In an embodiment, a first module is physically coupled to only a second module. In an embodiment, a first module is physically coupled to a plurality of modules.

[0024] In an embodiment, the bond is made of a material selected from the group consisting of halogen-free flame-retardant (HFFR) materials, polyester, polyurethane, polycarbonate, polyolefin, and polyvinyl chloride. The material of the bond is same as the material of the module in the optical fiber cable.

[0025] In an embodiment, the bond is intermittent along the length of the first and second module. In an embodiment, the bond is continuous along the length of the first and second module. In an embodiment, the plurality of bonds in the optical fiber cable is intermittent. In an embodiment, the plurality of bonds in the optical fiber cable is continuous. In an embodiment, at least at least one of the plurality of bonds in the optical fiber cable is intermittent. In an embodiment, at least at least one of the plurality of bonds in the optical fiber cable is continuous.

[0026] Advantageously, the bonds provided to physically couple a first and at least a second module of the optical fiber cable of the present disclosure provides for structural rigidity between the coupled modules. Advantageously, the bonds provided to physically couple a first and at least a second module of the optical fiber cable of the present disclosure reduces the requirement for additional binding components, such as binder yarns. Advantageously, as the bond material provided to physically couple a first and at least a second module of the optical fiber cable of the present disclosure is same as the material of the modules, the bonds do not compromise the flexibility of the modules. Advantageously, as the bond material provided to physically couple a first and at least a second module of the optical fiber cable of the present disclosure is same as the material of the modules, the manufacturing process is economical, faster, and of reduced complexity.

[0027] In an embodiment, the length of each of the plurality of bonds physically coupling a first and second module of the plurality of modules of the optical fiber cable is the same. In an embodiment, the length of at least one of the plurality of bonds physically coupling a first and second module of the plurality of modules of the optical fiber cable is different from at least a second bond. In an embodiment, the dimensions of each of the plurality of bonds physically coupling a first and second module of the plurality of modules of the optical fiber cable are the same. In an embodiment, the dimensions of at least one of the plurality of bonds physically coupling a first and second module of the plurality of modules of the optical fiber cable is different from at least a second bond. In an embodiment, the bond has a circular cross-section. In an embodiment, the bond has an oval cross-section. In an embodiment, the bond has a crescent crosssection. In an embodiment, the bond has a concave or convex cross-section. In an embodiment, the bond has a flat cross-section. In an embodiment, the bond can have any other polygonal crosssection. It is to be understood that the shape of the bond cross-section is not a limiting feature of the present optical fiber cable of the present invention.

[0028] In an embodiment, the thickness of the bond is configured such that the bond can be easily broken with hands without requiring any tool. In an embodiment, the thickness of the bond is preferably less than the wall thickness of the module. In an embodiment, the bond has a notched cross-section. In an embodiment, the notch is V-shaped, having a reduced thickness in center to facilitate easy separation of modules physically coupled via the bond.

[0029] In an embodiment, at least one of the plurality of modules further comprises at least a colored yarn member. In an embodiment, each of the plurality of modules further comprises a colored yarn member. In an embodiment, two colored yam members comprised in the plurality of modules of the optical fiber cable are the same color. The colored yarn member is provided for ready visual identification of modules as well as acts as a ripcord for ease of stripping of module. Additionally, the colored yarn member may also be coated with water-blocking materials to prevent ingression of water or moisture within the module.

[0030] In an embodiment, one or more of the plurality of modules further comprises a water blocking material to prevent ingress of water. In an embodiment, the water blocking material is a water swellable yarn member. In an embodiment, the yarn member can be colored. In an embodiment, the water blocking material is a water blocking gel. In an embodiment, the water blocking material is applied over the plurality of optical fibers as a powder. In an embodiment, the water blocking material is applied on an inner surface of the module.

[0031] In an embodiment, each of the modules of the plurality of modules comprised in the optical fiber cable has substantially circular cross-section. In an embodiment, each of the modules of the plurality of modules comprised in the optical fiber cable has a non-circular cross-section. In an embodiment, each of the modules of the plurality of modules comprised in the optical fiber cable have polygonal cross-section. In an embodiment, each of the modules of the plurality of modules can have a cross section different from each other.

[0032] In an embodiment, the optical fiber cable further comprises at least a strength member. In an embodiment, the one or more strength member is disposed longitudinally along with the plurality of modules. In an embodiment, the optical fiber cable comprises a single strength member. In an embodiment, the optical fiber cable comprises a plurality of strength members. In an embodiment, where the optical fiber cable comprises a plurality of strength members, the strength members are stranded. In an embodiment, the stranding is helical. It is understood that the stranding of the plurality of strength members is not limited to helical, and can be in any other manner known in the art, and is not a limiting feature of the present disclosure. In an embodiment, the one or more strength member is disposed along a central axis of the optical fiber cable. In an embodiment, the one or more strength member is disposed off the central axis of the optical fiber cable. In an embodiment, the one of more strength member is aramid yarn. In an embodiment, the one or more strength member is of fiberglass material. In an embodiment, the one or more strength member is made of steel. In an embodiment, the one or more strength member is FRP (fiberglass- reinforced plastic) material, ARP (aramid-reinforced plastic) material or any other similar material.

[0033] In an embodiment, the optical fiber cable comprises an outer sheath encapsulating the plurality of the modules. The plurality of modules are configured to confirm to the shape of the inner cavity of the outer sheath of the optical fiber cable. In an embodiment, the outer sheath material is selected from the group consisting of plastic, polymer, and rubber. For examples, the outer sheath can be made of HDPE material, LDPE material, LLDPE material, or combinations thereof in varying ratios. It is to be understood that the material of the outer sheath is not a limiting feature of the optical fiber cable of the present disclosure. Any other material known and / or used for the purposes of sheathing of optical fiber cable can be readily employed.

[0034] In an embodiment, the optical fiber cable may comprise one or more layers encapsulated within the outer sheath. The one or more layers are located between the plurality of the modules and the outer sheath. In an embodiment, the additional layer can be an armored layer. It is understood that the armored layer is not a limiting feature of the present disclosure and that a person skilled in the art can use any armored layer material and configuration known in the art as per end user requirement / specifications. In a non-limiting disclosure, the armor layer can be corrugated or spiral. In an embodiment, the armor layer can be made of a metal. In another embodiment the armor layer can be made of a dielectric material selected from the group consisting of FRP, ARP, IGFR, aramid yarn, polyvinylidene fluoride (PVDF), polyether-ether ketone (PEEK), polyvinyl chloride (PVC), flame-retardant polyethylene (FRPE), chlorinated polyvinyl chloride (CPVC), polytetrafluoroethylene (PTFE), Fiber-Reinforced Polymer (FRP), acrylonitrile butadiene styrene (ABS), low-smoke zero-halogen (LSZH) material, polybutylene terephthalate (PBT), polycarbonate (PC), polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), and combinations thereof.

[0035] In an embodiment, the additional layer can be a water blocking layer, which can be a tape material, yarn material, or powder material. Such materials are known in the art and do not limit the present disclosure.

[0036] In an embodiment, the outer sheath layer comprises one or more strength elements embedded in the outer sheath layer, for additional rigidity to the optical fiber cable. In an embodiment, the one or more strength element is selected from the group consisting of fiber reinforced plastic (FRP), aramid reinforced plastic (ARP), impregnated glass fiber reinforced (IGFR), and steel wires.

[0037] The present invention also provides an apparatus for manufacturing a plurality of modules, said modules as substantially described herein. The apparatus comprises an extrusion module configured to house a die and tip / wireguide, wherein said die comprises a plurality of first slots arranged on a first plane of the die, wherein the plurality of first slots extend through the length of the die; and at least a second slot arranged on the first plane of the die, wherein the second slot is adapted to couple a plurality of first slots, wherein the second slot extends through the length of the die, wherein the plurality of first slots are adapted to receive one or more optical fibers therethrough; and the plurality of first slots and second slots are adapted to receive a polymeric material to encapsulate the one or more optical fibers.

[0038] In an embodiment, the die comprises at least two first slot and at least one second slot coupling the two first slots. In an embodiment, the die comprises more than two first slot and at least two second slot, wherein any two of first slots are coupled with one or more second slot. In an embodiment, the die comprises any of at least five, seven, or ten first slots. In an embodiment, where the die has “n” number of first slots, the die has at least “n-1” number of second slots. In an embodiment, the plurality of first slots is also adapted to receive one or more yarn members, wherein the yam member is colored.

[0039] In an embodiment, the die is made of a material that has suitable chemical and thermal resistance to be used for manufacturing the optical fiber cable. In an embodiment, the die is used for extrusion processes at a temperature in a range between about 100 degrees Celsius (°C) and 400 °C. In an embodiment, the die is made of a material selected from a group consisting of metals, alloys, ceramics, and combinations thereof. Examples of the material comprises, without limitations, steel, aluminum, iron, brass, copper, ceramics, etc.

[0040] The present invention also provides a method for manufacturing an optical fiber cable, said optical fiber cable as substantially described herein. The method comprises applying a polymeric material layer on at least an optical fiber, preferably a plurality of optical fibers, through at least a first slot of a die to obtain a one or more modules, whereby a first module is physically coupled to at least a second module by at least a bond. The material is of the bond and the module is same and the bond is continuous with the module outer surface. In an embodiment, the plurality of modules and bonds are manufactured in a single continuous extrusion process.

[0041] As a next step, an outer sheath is extruded over the plurality of modules to encapsulate the plurality of modules to form the optical fiber cable. In an embodiment, the step of extruding outer sheath layer is preceded by encapsulating the plurality of modules with an armor layer. In an embodiment, the step of extruding outer sheath layer is preceded by encapsulating the plurality of modules with a water blocking layer.

[0042] Using this method, the outer sheath can be extruded in tandem with the manufacturing process of the modules in same assembly line. Additionally, this process helps in reducing an additional step of binding the modules before sheathing process and / or manufacturing each modules individually and feeding individually manufactured modules to the sheathing line to manufacture a multi-module optical fiber cable.

[0043] In an embodiment, the plurality of modules coupled via bonds are configured to take a shape of inner cavity of the outer sheath during extrusion process. This is accomplished due to the arrangement of bonds in between the modules. Further, the material used for the manufacturing of modules and bonds is flexible enough to allow re-arrangement inside the cavity of the outer sheath and to take desired shape.

[0044] In an exemplary example of the present invention, FIG. 1A illustrates a schematic perspective view of an optical fiber cable 100 in accordance with an embodiment of the present invention. The optical fiber cable 100 comprises a plurality of modules 102 encapsulating a plurality of optical fibers 104. For instance, the optical fiber cable 100 comprises a first module 102-1 and a second module 102-2. The plurality of modules is physically coupled via bonds 106. For instance, first module 102-1 and second module 102-2 is physically coupled via a single bond 106. The optical fiber cable 100 also comprises strengthening yarn member 108. The plurality of the modules 102 are encapsulated within an outer sheath member 110. Though not shown, the optical fiber cable 100 may comprise additional layers, such as armor layer and water inhibiting layer, each of which may be arranged concentric to the inner surface of the outer sheath layer 110.

[0045] In another exemplary embodiment, FIG. IB illustrates the schematic view of a preferred arrangement of a plurality of modules 120-1 of the optical fiber cable 100. As seen in the preferred arrangement, there is provided a plurality of modules whereby each of the plurality of modules is coupled with at least an adjacent module via a bond. In some cases, a module can have a single bond coupling to a single adjacent module. In some cases a single module can be coupled with a plurality of adjacent modules.

[0046] In another exemplary example, FIG. 1C illustrates the schematic view of an arrangement of a plurality of modules 120-2 through 120-6 of the optical fiber cable 100. As seen in the various module arrangements, there is provided a plurality of modules whereby each of the plurality of modules is coupled with at least an adjacent module via a single bond. In some cases, a module can have a single bond coupling to a single adjacent module. In some cases a single module can be coupled with a plurality of adjacent modules. While the various arrangements only show a single bond between any two modules, however, multiple bonds between the same pair of modules is also possible and contemplated.

[0047] FIG. 2A illustrates the schematic sectional view of a preferred die 200 of an apparatus for manufacturing modules for optical fiber cable 100. As seen in FIG. 2, the die face 204 comprises a plurality of first slots 202 (such as 202-1 and 202-2) and a second slot 206-1 connecting the plurality of first slots 202-1 and 202-2. The die 200 further comprises a central slot. The central slot is preferably attached with the tip / head of the extrusion apparatus. In an alternative embodiment, central slot is supported using wireguide. The first slots 202-1, 202-2 are adapted to receive a plurality of optical fibers therethrough. The first slots 202-1, 202-2 and second slot 206- 1 are adapted to receive a polymeric material, whereby the polymeric material may be extruded through the die 200, whereby the optical fibers are encapsulated by the polymeric material to form the modules as described herein. Subsequently, the plurality of modules can be bunched and an outer sheath material can be extruded over the plurality of modules to obtain the optical fiber cable of the present invention. Prior to extrusion of outer sheath material over the plurality of modules, one or more additional layers can be applied over the plurality of modules. As disclosed above, the additional layer can be selected from the group consisting of armored layer, water-blocking layer, strength members or combination thereof.

[0048] Similar to FIG. 2A, FIG. 2B illustrates the schematic sectional view of another embodiment of die 200 of an apparatus for manufacturing modules for optical fiber cable 100.

[0049] While the preferred embodiments of the present disclosure have been described hereinabove, it may be appreciated that various changes, adaptations, and modifications may be made therein without departing from the spirit of the disclosure and the scope of the appended claims. It will be obvious to a person skilled in the art that the present disclosure may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments may be considered in all respects only as illustrative and not restrictive.

[0050] LIST OF REFERENCE NUMERALS

[0051] 100 Optical fiber cable

[0052] 102 Modules

[0053] 104 Optical Fibers

[0054] 106 Bond

[0055] 108 Strengthening Member

[0056] 110 Outer Sheath

[0057] 120-1 to 120-5 Arrangement of Modules 102

[0058] 200 Die

[0059] 202 (202-1, 202-2) First Slot

[0060] 204 Die Face

[0061] 206-1 Second Slot

Claims

I / We Claim:

1. An optical fiber cable (100) comprising a plurality of modules (102), said modules (102) comprising one or more optical fibres (104), characterized in that a first module (102-1) is physically coupled to at least a second module (102-2) by at least a bond (106), wherein the material of the bond (106) and the modules (102) is same.

2. The optical fiber cable (100) as claimed in claim 1, wherein the bond (106) is continuous along the length of the module (102),3. The optical fiber cable (100) as claimed in claim 1, wherein the bond (106) is intermittent along the length of the module (102).

4. The optical fiber cable (100) as claimed in claim 1, wherein the bond (106) has a notched cross-section to facilitate easy separation of modules.

5. The optical fiber cable (100) as claimed in claim 1, wherein each of said modules comprise at least a coloured yarn member.

6. The optical fiber cable (100) as claimed in claim 1, comprising at least a strength member (108).

7. The optical fiber cable (100) as claimed in claim 1, wherein the plurality of modules (102) is configured to conform to the shape of inner cavity of an outer sheath (110) of the optical fiber cable (100).

8. The optical fiber cable (100) as claimed in claim 7, comprising at least one or more layers encapsulated within the outer sheath (110), wherein, the one or more layers is selected from the group consisting of armored layer, water-blocking layer, strength members or combination thereof.

9. An apparatus for manufacturing an optical fiber cable (100), comprising an extrusion module configured to house a die (200), wherein said die (200) comprises:- a plurality of first slots (202) arranged on a first plane (204) of the die (200), wherein the plurality of first slots (202) extend through the length of the die (200); and- at least one second slot (206) arranged on the first plane (204) of the die (200), wherein the second slot (206) is adapted to couple a plurality of first slots (202-1, 202-2), wherein the second slot (206) extends through the length of the die (200), wherein- the plurality of first slots (202) are adapted to receive one or more optical fibres (104) therethrough; and- the plurality of first slots (202) and second slot (206) are adapted to receive a polymeric material to encapsulate the one or more optical fibers.

10. A method (300) of manufacturing an optical fiber cable (100), comprising:- applying a polymeric material layer on at least an optical fibre (104) through a plurality of slots (202) of a die (200) to obtain a plurality of modules (102), wherein a first module (102-1) is physically coupled to at least a second module (102-2) by a bond (106), wherein the material of the bond (106) and the modules (102) is same, and wherein the bond (106) is continuous with the module outer surface; and- extruding a sheath (110) to encapsulate the plurality of modules to obtain said optical fiber cable (100).

11. The method (300) as claimed in claim 10, wherein said modules (102) further comprises at least a coloured yarn member.

12. The method (300) as claimed in claim 10, wherein the plurality of modules (102) and bonds (106) are manufactured in a single continuous extrusion process.

13. The method (300) as claimed in claim 10, wherein the optical fibre (104) is selected from at least one of loose fiber, rollable ribbon, flat ribbon, and intermittently bonded ribbon (IBR).

14. The method (300) as claimed in claim 10, wherein the polymeric material is selected from at least one of halogen-free flame retardant (HFFR) materials, polyester, polyurethane, polycarbonate, polyolefin, and polyvinyl chloride.

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