GEL COMPOSITIONS

Abstract: The invention relates to a composition which comprises a dispersion of micro spheres in a gel comprising an oily base and an organic polymeric gelling agent.

Description: GEL COMPOSITIONS This invenϋon relates to gel compositions for filling cables, such as communication cables, in particular to gel compositions containing micro spheres, and to methods of preparing such gels Background of the Invention Communications cables typically compose a signal-conducting core surrounded by a protective sheath The core can, for example, conduct light signals or electπcal signals In many cables the space between the conductor and sheath contains a filler, the role of which is to protect and cushion the core from external forces that might be produced by, for example, bending or coiling, particularly in the case of fibre-optic cables A further role of the filler is the prevention of water mgress which is particularly pertinent should the core compose a metal such as copper In order to fulfil these requirements, the filler must display a number of characteπstics The filler must be of sufficient viscosity in order to allow lateral movement of the core which occurs during, for example, bending, coiling or laying The viscosity must however not be so low as to allow a drip wise loss of filler during vertical laymg of cables Moreover, this balance of properties must be maintained over a temperature range of -40 to +80°C The filler must be formulated to be chemically compatible with cable grade polymers. which includes not only the cable sheath but also coatmgs typically found on optical fibres The filler should also show a high degree of elasticity m order to absorb the force of impacts that the cable sheath may undergo during its operating lifetime Relatively high ambient temperatures can be reached through fabπcation of such cables resulting m thermal expansion of the filler which then leads to the formation of holes and cavities on cooling Such holes and cavities canpotenUally become a water path which in fibre opnc cables can lead to attenuation of the light wave guide Thus cable fillers should ideally show low thermal conductivity For electπcal applications or cores transmittmg electπcal signals, it is advantageous if the filler has a low permitivity thus insulating the conducting core This has the additional benefit of rendering the filler hydrophobic thereby protectmg the core from water mgress The anti-d p resistance of fillers can be improved by reducmg their specific weight Finally, for easy handling, it is preferred if the filler is semi-dry to the touch, rather than sticky Existing fillers used m telecommunication cables mclude oil gels which are pomanly blends of oils and gelling agents In application, they penetrate between bundles of, for example, denseh packed insulated copper conductors and in so domg msulate them from moisture The oil. which composes a major part of the blend, can be a naphthemc or paraffimc processing oil. a mineral oil. a synthetic product such as a polybutane or a sihcone oil Gellmg agents include waxes, silicic (silica gels) acids, fumed silica, fatty acid soaps and thermoplastic elastomers Typically the gellmg agent composes less than 10% of the whole One particular family of thermoplastic elastomers marketed under the trade mark 'Kraton ' (Shell Chemical Company), composes di-block. tπ-block or multi-arm molecular configurations of rubber and polystyrene segments US 5 657 410 descobes an optical transmission element which mcludes a filler composmg between 80% and 95% by weight of a monomeoc plasticizer having a molecular weight m the range 200-2000 grams per mole Such monomeoc plasticizers include esters of phthalates, tomelhtates. phosphates and fatty esters Additional substances may also be added such as thickeners The thickener can take the form of small spheres Hollow spheres are prefeoed due to their great compressibility and easy processibihty Thixotropic agents may also advantageously be added They mclude finely divided or fumed silica, alumina, and bentomtes as well as mixtures of these substances The use of micro spheres, e g hollow micro spheres, in cable filling compounds is also descobed in US 5 698 615 In this disclosure the cable filler composes a substantially dry hydrophilic composition containing inter aha , in addition to the micro spheres, water absorbent swellable powder particles, preferably of particle size range 1-30 μm and a "parting powder" having particles of preferably 1/lOOth the size of the swellable powder particles Due to the hydrophilic nature of the swellable powder particles, the composition always retains some water The parting powder particles are disposed between the swellable powder particles to prevent agglomeration as the swellable polymer particles absorb water Suitable swellable powder particles are those based on the polyacryhc acid sodium salt The parting powder particles are typically inorganic powders such as talcum, mica, graphite and silicates The absorption of water by the swellable powder particles transforms the dry composition into a gel which seals the core from further water mgress The compositions can also contain a small amount of an oil or an adhesive to reduce any potential dust hazard WO 99/15582 discloses a composition which mcludes expandable hollow micro spheres for use m encapsulation of for example semi-conductor chips Such hollow micro spheres, similar in morphology to the micro spheres disclosed m US 5 657 410 and US 5 698 615. compose a polymeoc shell encapsulating a blowing agent When heated, the polymeπc shell of the expandable micro spheres gradually softens and the liquid blowmg agent, typically isobutane, starts to evaporate thus expanding the microsphere A light wave guide lead is disclosed in US 5 335 302 which composes at least one light wave guide accommodated m a protective sheath and embedded m a pasty filling matenal contaimng small micro spheres The small micro spheres, which can be solid and ogid, solid and elastic or hollow and elastic, are included as fillers to reduce the cost, and to provide improved rheological and cushioning properties A prefeoed filler composes an oil, a thixotropic agent (for example fumed silica) and an unspecified organic thickener Summary of the Invention In one aspect, the present mvention provides a composition, particularly a composition suitable for use as a cable filler, which composes a dispersion of micro spheres m a gel composmg an oily base and an organic polymeoc gellmg agent In another aspect, the mvention provides a composition, particularly a composition suitable for use as a cable filler, which composes a dispersion of micro spheres m a gel composmg an oily base and an organic polymeoc gellmg agent, the composition contaimng substantially no thixotropic agent other than the organic polymeoc gellmg agent In a further aspect, the mvention provides a composition, particularly a composition suitable for use as a cable filler, which composes a dispersion of micro spheres m a gel composmg an oily base and a polymeoc gellmg agent wherem the polymeoc gellmg agent compπses, consists essentially of, or consists of a thermoplastic elastomer Another aspect of the mvention provides a composition, particularly a composition suitable for use as a cable filler, which composes a dispersion of micro spheres m a gel composmg an oily base and a polymeoc gellmg agent wherem the polymeoc gellmg agent compπses, consists essentially of, or consists of a thermoplastic elastomer other than polystyrene-isoprene rubber Yet another aspect of the mvention provides a composition, particularh a composition suitable for use as a cable filler, which composes a dispersion of micro spheres in a gel composmg an oily base and a polymeoc gellmg agent wherem the polymeoc gellmg agent composes, consists essentially of, or consists of a thermoplastic elastomer, excluding compositions containing polystyrene-isoprene rubber and an orgamc thickener A further aspect of the mvention provides a composition, particularly a composition suitable for use as a cable filler, which composes a dispersion of micro spheres in a gel composmg an oily base and a thermoplastic elastomer as a gellmg agent, the composition contaimng substantially no thixotropic agent m addition to the thermoplastic elastomer Another aspect of the present mvention is a gel composition composmg a dispersion of orgamc microspheres m a gel composmg an oily base and a thermoplastic elastomer, the gel containing substantially no thixotropic agent in addition to the thermoplastic elastomer and being substantially free from silica, for example fumed silica A particular embodiment of the mvention is a composition, particularly a composition suitable for use as a cable filler, which composes a dispersion of micro spheres m a gel compπsmg an oily base and an orgamc polymeπc gellmg agent wherem the gel is substantially free of fumed silica The gels of the mvention may additionally contain an anti-oxidant The oily base can compose a hydrocarbon oil or a sihcone oil Particularly prefeoed hydrocarbon oils include white mineral oils and poly(θ--olefin) synthetic oils The oily base typically constitutes 1-99% by weight of the gel, more preferably 50-99% by weight of the gel, m particular 80-99% by weight of the gel Examples of thermoplastic elastomers clude thermoplastic rubbers The thermoplastic elastomer can be a copolymer, for example a block copolymer possessing a di-block, a to- block, or a multi-arm molecular configuration In one particular embodiment, the blocks are composed of either rubber or polystyrene The rubber can be a saturated olefin rubber composed of ethylene, propylene or butylene monomer umts Alternatively, the rubber can be an unsaturated olefin rubber compπsmg butadiene or isoprene monomer umts Particular examples of thermoplastic elastomers include styrene-ethylene butvlene styrene to-block copolymer (SEBS), styrene-ethylene/propylene di-block copolymer (SEP) ethylene/propylene multi-arm copolymer (EP). styrene-butadiene-styrene to-block copolymer (SBS) and styrene-isoprene-styrene to-block copolymer (SIS) Commercially available thermoplastic elastomers mclude the copolymers available under the trade mark "Kraton" from Shell The polymeric gellmg agent is typically used in proportions m the range 1-10% by weight of the composition, more preferably, m the range 2-9% by weight of the composition, m particular m the range 3-8% b\ weight of the composition The micro spheres can be. for example, solid ogid micro spheres, solid elastic micro spheres or compressible hollow micro spheres Solid ogid micro spheres can be formed from a thermosetting resm such as melamme-formaldehyde resm which has a relatively low thermal expansion coefficient and m use would tend to lower the overall expansion coefficient of the gel This is particularly advantageous where the gel may be heated during manufacture of, for example, fibre optic leads During such processes, conventional mateπals tend to expand when heated leaving holes or cavities around the wave guides on coolmg The holes or cavities can, under certain conditions, lead to an mcrease in attenuation of the light wave guides The melamme-formaldehyde micro spheres, available from Ubitek Company of Uchte, preferabh have a diameter of < lOμm , m particular < lμm Examples of solid elastic micro spheres are those compπsmg polyisoprene The polyisoprene is not only elastic m its own πght but can additionally absorb considerable quantities of the oily base thereby becoming even more elastic The mean diameter of the micro spheres is preferably < 10 μm, more preferably < lμm One prefeoed embodiment of the mvention uses compressible hollow micro spheres each compπsmg a polymeπc shell encapsulatmg a blowmg agent The polymeπc shell is generally, formed from a copolymer. for example a copolymer of vmyhdene chloode and acrylomtπle The blowmg agent can, for example, be isobutane or isopentane In addition, the micro spheres can be expanded or unexpanded The polymeπc shell of the unexpanded micro spheres softens on heatmg, so allowing the evaporating blow g agent to expand the volume of the micro spheres Such hollow micro spheres whether expanded or initially unexpanded. display a high degree of elasticity and additionally have a low specific weight Use of such micro spheres m the gels disclosed in this mvention is advantageous m that they lower the overall specific weight of the gels and thus reduce or eliminate dπp-out during vertical laying of the cable The hollow nature of the micro spheres means that the proportion of solid mateπal is very low relative to the volume Thus their addition to the gels of the mvention leads to a reduction in the overall thermal conductivity and a reduced likelihood of decomposition of any of the components of the gel or the creation of voids under the elevated temperatures reached during cable manufacture The supeπor elastic properties of the hollow micro spheres over their solid counterparts gives improved protection to, for example, light wave guides during conveying, coiling or laying Additionally, the problem of attenuation of light waveguides due to the presence of holes or cavities within the cable filling is also reduced as any mcrease m volume of the bulk of the filler due to heatmg during cable manufacture is matched by a converse reduction m the volume of the hollow micro spheres Due to the compressible nature of such hollow micro spheres, their typical diameters are greater than those of their solid counterparts In fibre optic cable applications, diameters in the range of the diameter of the light wave guide can be used For expanded hollow micro spheres, the diameters will typically lie m the range 1-200 μm, more usually less than 100 μm, typically less than 75 μm, for example 15 to 55 μm For unexpanded hollow micro spheres, the mean diameter poor to expansion is typically m the range up to 50μm, more usually less than 30 μm. for example in the range 10 to 20 μm The volume proportion of the micro spheres generally differs for solid and hollow counterparts The solid micro spheres are typically employed m the volume range 1-50% by volume of the gel (v/v), more preferably m the range 5-50% v/v Where hollow micro spheres are used, they are typically present in the range 1-95% v/v, more preferably 5-95% v/v, m particular 50-95% v/v, the foregomg figures referring to the expanded volumes The anti-oxidant can be selected from those commonly used in the art Phenolic anti- oxidants are preferred The anti-oxidant is typically present m an amount 0 01-1% w/w, for example 0 1-1% w/w In a further aspect, the mvention provides a composition as herembefore defined for use as a cable filler In another aspect, the mvention provides a cable, such as a communications cable. containing a filler as herembefore defined In a still further aspect, the mvention provides a cable composmg a conductmg core suoounded by a sheath, a composition as herembefore defined being disposed bet een the conductmg core and the sheath The conductmg core can be, for example, an electocal conductor or a light conductor The electocal conductor can be, for example, a conductor for conductmg electocal signals such as telephone signals In a further aspect, the mvention provides a process for making a cable composmg a conductmg core and a sheath, the process compπsmg the step of extruding the cable sheath onto the conductmg core and mterposmg a composition as herembefore defined between the conductmg core and sheath during the extrusion step In another aspect, the mvention provides a process for preparing a gel as herembefore defined, the process composmg (a) heatmg the oily base to a temperature m the range 110°C to 120°C, (b) addmg the polymeoc gellmg agent to the oily base and blendmg to form a mixture, (c) coolmg the mixture to a temperature of less than 90°C, (d) addmg and blendmg in the micro spheres, and optionally (e) adding and blendmg m an anti-oxidant and/or (f) maintaining the mixture under vacuum to remove entrapped gas In a prefeoed embodiment, the process composes (I) blending at least one oil m a heating-blending tank, (u) heatmg the blended oils to 110-120°C m a stioed heating-blending tank, (in) addmg and blendmg the polymeπc gellmg agent to the oily base under high shear for no more than one hour after transfer of the oily base to a blending-coohng tank, allowing the temperature of the blend to πse to more than 120-130°C, (IV) coolmg the blend to <90°C and transferring to a stirred mam reactor, (v) addmg and blendmg an anti-oxidant, (vi) adding and blendmg the micro spheres, drawn to the reactor under vacuum or pumping, for at least two mmutes, (vn) mamtammg the vacuum for at least another 10 mmutes m order to effect removal of air bubbles pπor to release of the finished gel Although the temperature of the mixture is typically < 90°C after coolmg. more preferably it is < 80°C, m particular it is < 70°C Further and particular aspects of the mvention are as set out m the claims appended hereto Brief Description of the Drawings The mvention will now be illustrated, but not limited, by reference to the particular embodiments shown m the accompanying drawings, m which Figure 1 shows a cross-sectional view of an electπcal cable, and Figure 2 shows a cross-sectional view of an optical cable, Figure 3 is a graph of viscosity against shear rate for the composition of Example 1 at 25°C, and Figure 4 is a graph of viscosity against shear rate for the composition of Example 2 at 25°C Detailed Description of the Preferred Embodiments Figure 1 shows a cross-sectional view of an electπcal cable 11, compπsmg, m this example, four electπcal leads 13 encased m cladding 12 The electπcal leads 13 themselves compπse an electπcal conductor 14. preferably of copper, and an outer msulation 15, typically of polyethylene Interspersed bet een the electncal leads 13 and the outer cladding 12, is a filler gel composition 16 In this embodiment, the filler composition can compπse an oily base, a thermoplastic rubber as polymeπc gellmg agent and micro spheres dispersed therein and optionally an anti-oxidant The electπcal cable, typically composmg a copper core, can be used for the purposes of telecommunications or distπbution of electπcity Although Figure 1 shows a cross-sectional view of an electπcal cable compπsmg four conductors m a star quad configuration, it will be appreciated that cables having a vaπety of different configurations can be used as alternatives to the configuration shown Figure 2 shows an optical cable 21 compπsmg three optical fibre buffer tubes 23 encased m claddmg 22 The optical fibre buffer tubes 23 themselves consist of an optical fibre 24 provided with a protective coatmg 26 and a protective sheath 25 The filler composition 27 is disposed between the coated optical fibre and the protective sheath Additionally, it fills the mterstices formed between mdividual buffer tubes and between the buffer tubes and the internal surface of the cable claddmg Examples of specific gels suitable for use m cables, such as the cables illustrated in Figures 1 and 2 are as follows EXAMPLE 1 A gel filler was prepared having the following composition The gel filler of this example is suitable for filling the mterstices between the tubes and conductors (flooding) and is not m direct contact with the fibre guides The gel was prepared as follows The oily base was mtroduced into a stirred heating-blending tank and heated to 110- 120°C before transferring to a high shear blending-cooling tank, whereupon the thermoplastic elastomer (Kraton) (m the form of granules) was added The mixture was blended under high shear conditions usmg a multi-purpose immersion type mixer emulsifier (Silverson Machines Limited, Model GDD 25) for no more than 60 mmutes Duong the blendmg process, the temperature of the mixture was allowed to πse to 120-130°C The mixture was cooled by means of a cold water chiller system, and the chilled mixture was transferred to a stioed mam reactor where the anti-oxidant was added A vacuum as then created mside the reactor m order to suck m the micro spheres which were mixed mto the blend over a peood of at least two mmutes The vacuum was mamtamed for at least a further ten mmutes in order to effect removal of any air bubbles The vacuum was then released, the stioer switched off and samples taken poor to release of the finished gel from the mam reactor The product was characteosed by a number of tests, the results of which are summaosed m Table 1 below The thermal conductivities refeoed to m the table were determined as follows Specimen discs were created by scooping the gels mto a pair of nylon rings of mean internal diameter 70 1 mm and mean thickness 10 03 mm and placmg cling film above and below A small cooection was made to allow for the extra interface mtroduced by the clmg film The thermal conductivity of the specimens was measured usmg a 76 mm guarded hotplate A pair of specimen discs were mounted, under the pressure of two cooled plates, on either side of a guarded heater plate The cooled plates were mamtamed at a constant temperature to better than ±0 05°C The surfaces of the plates had emittances of better than 0 9 The temperature of the annular guard on the heater plate was matched to that of the central part to better than ±0 01°C m order to minimise lateral heat flow m the specimens The heater plate and the specimens were msulated with a glass fibre blanket to further reduce edge heat losses The temperature drop through the specunens was fixed at 14°C and about 5 hours was allowed for thermal equi boum to be established before final readings were taken The aging test was deπved from YD/T839 4- 1996 (PRC Method) except that the temperature and duration of the test was altered Table 1 Physical Properties Property Value Test Method Density (20°C) g/ml 0 356 ASTM D 1475 Viscosity (100s l . 25°C) Pa s 23 63 Haake VT500 Tube drainage (7mm ιd/80°C/24 hrs ) Pass EIA/TIA-455-81A Cone Penetration (23°C) dmm 335 ASTM D937 Cone Penetration (-30°C) dmm 167 ASTM D937 Cone Penetration (-40°C) dmm 120 ASTM D937 Oil separation (80°C/24 hrs ) % wt 0 FTM791 (321 ) Volatile loss (80T/24 hrs ) % w/w 0 17 FTM791(321) OIT (190°C) rmn 34 75 ASTM D3895 Thermal conductivity (23°C) W/m K 0 077 see above Thermal conductivity (80°C) W/m K 0 078 see above Hydrogen generation (80°C/24hrs ) μl/g 0 010 Acid Value mgKOH/g 0 036 BS2000 Agmg (100°C/240 hrs ) Pass see above UV exposure (25°C/14 days) Pass Temperature exposure (240°C/5 nuns ) Pass OIT = Oxidative mduction time Table 1 shows that the density of the gel is low which contobuted to good anti-dop properties (measured at 80°C) Low temperature performance was assessed by cone penetration at -40°C whilst high temperature performance was tested by a combmation of the dop test, oil separation and volatile loss tests all earned out at 80°C and the oxidative mduction time test earned out at 190°C An oxidative mduction time m excess of 20 mmutes is desirable The results mdicate that the gel has a workmg temperature range of -40 to +80°C Furthermore the rheological behaviour of the gel. shown m figure 3, is thixotropic (shear thinning) allowing for cold pumping and processmg. and thus cable filling m the absence of voids created by gel shrinkage Thermal conductivity was determined at 23°C and 80°C The values for the conductivity were low reflecting the low density of the gel, and vaπed little with temperature suggesting a material possessmg a disordered structure The good insulating properties indicated a mateπal possessmg good resistance to thermal decomposition that can occur at the elevated temperatures reached during cable manufacture In addition, the gel would be less sensitive to the thermal expansion and contraction that can take place during cable manufacture leadmg to the formation of voids m the cable filling For purposes of compaoson, the thermal conductivities of a range of mateoals are given m Table 2 Table 2 Thermal Conductivities of Vaoous Mateoals Mateoal Thermal conductivity W/m K Comment Aluminium 200 Very good conductor Water 0 6 Olive oil 0 17 Paraffin 0 15 Air 0 024 Very good insulator The gel showed good aging properties and uv and temperature resistance There was also low hydrogen gas generation EXAMPLE 2 A similar gel filler was prepared m a similar manner to that described m Example 1 but with a different grade of mineral oil The gel was suitable for use m small pair telephone copper cable filling and flooding applications The gel was subject to a number of physical tests The results of the tests were similar to those of the composition of Example 1 and therefore only the electocal properties are quoted m Table 3 Table 3 Physical Properties Property Value Test Method Dielectoc constant (23°C) 1 62 ASTM D924 Dielectoc dissipation factor (1 MHz) 4 4 x l0 4 ASTM D924 Volume resistivity (23 °C) Ohm cm 2 8 x 10 15 ASTM D257 Break down voltage kV 86 The gel is characteosed by a low relative permitivity (1 62) and a high volume resistivity (2 8x10 15 Ohm cm) For purposes of compaoson, the relative permitivities of a number of mateoals are given m Table 4 Table 4 Relative Permitivities of Vaoous Mateoals Mateoal Relative permitivity Air (normal pressure) 1 0005 Paraffin wax 2 Paraffin oil 4 7 Glass 5-10 Methyl alcohol 32 Water 81 EXAMPLE 3 A gel suitable for use m filling loose tubes and interstitial filling between πbbons and open slotted cores, was prepared m a similar manner to that descπbed m example 1 The formula for this gel is set out below The poly α-olefin oil is also supplied by BP/Mobil as SHF 61 The gel was subject to a number of physical tests The results of the physical tests, which were similar to the results of the composition of Example 1, are shown in Table 5 In addition, the tensile strength and coatmg stπp force of optical fibres were tested according to the standards FOTP - 28 and FOTP - 178 respectively The optical fibre was CPC6 manufactured by Siecor The tests were earned out after agemg of the fibres m forced air chambers for 30 days at 85±1 °C whilst immersed in the gel Measurements were earned out at 20 °C and 70% relative humidity The tensile strength was measured on thirty 0 5mm samples from four different groups at a rate of elongation of 500±50 mm mm 50mm samples were used for the coating stπp force tests usmg a stπppmg tool at a speed of 500±50 mm/mm Average tensile strength and coatmg stπp force values for a control sample were 68 89 N and 3 61 N respectively Table 5 Physical Properties Property Value Test Method Density (20°C) g/ml 0 438 ASTM D 1475 Viscosity (200s 25°C) Pa s 7 95 Haake VT500 Tube dramage (7mm ιd/80°C/24 hrs ) Pass EIA/TIA-455-81A Cone Penetration (23°C) dmm 396 ASTM D937 Cone Penetration (-40°C) dmm 250 ASTM D937 Oil separation (80°C/24 hrs ) % wt 0 FTM791(321) Volatile loss (80°C/24 hrs ) % w/w 0 06 FTM791(321) OIT (190°C) mm 31 04 ASTM D3895 Thermal conductivity (23°C) W/m K 0 077 see example 1 Thermal conductivity (80°C) W/m K 0 078 see example 1 Hydrogen generation (80°C/24hrs ) μl/g 0 015 Relative permitivity (50Hz. 25°C) 1 65 ASTM D 150 Volume resistivity (23 °C) Ohm cm 19xl0 ASTM D257 Tensile strength (20 °C/70% RH) N 65 07 FOTP - 28 Coatmg stnp force (20°C/70% RH) N 3 88 FOTP - 178 Ag g (100°C/240 hrs ) Pass see example 1 UV exposure (25X/14 days) Pass Temperature exposure (240°C/5 nuns ) Pass OIT = Oxidative mduction time The shear sensitive behaviour of the viscosity is illustrated m Figure 4 and shows that the gel is thixotropic or shear thinning This gel, although of lower viscosity than the gel of example 1, still passed the dramage test The low temperature performance, characteπsed by the cone penetration at -40°C, was exceptional This is particularly important as this gel is used m direct contact with optical fibres and must maintain flexibility at low temperatures to avoid applying stresses to the aforementioned fibres or micro bending caused by contractio which can lead to an mcrease in attenuation The tensile strength and coatmg stπp force results suggested that there was no deteπoration m the mechamcal strength of the fibres or degradation m the fibre coating after exposure to the gel EXAMPLE 4 This gel, formulated for filing loose tubes and interstitial filling between ribbons and open slotted cores particularly for use with pohpropylene cable polymers, was prepared in a similar manner to that described in example 1. The formula for this gel is set out below: The resulting gel was subject to a number of physical and chemical tests, the results of which are summarised in Table 6 below. The gel was tested for compatibility with polypropylene using the following method: Six 50mm long samples of buffer loose tubes were weighed to 0.0000 lg. Five of the samples were subsequently immersed in the gel and all six aged in an air-circulated oven at 80°C for two weeks. The samples were then re-weighed. Table 6: Physical Properties Property Value Test Method Density (20°C) g/ml 0.51 ASTM D 1475 Viscosity (100s \ 25°C) Pa.s 32.86 Haake VT500 Tube drainage (7mm id/80°C/24 hrs.) Pass EIA/TIA-455-81A Cone Penetration (23°C) dmm 340 ASTM D937 Cone Penetration (-40°C) dmm 280 ASTM D937 Oil separation (80°C/24 hrs.) % wt. 4.97 FTM791(321) Volatile loss (80°C/24 hrs.) % w/w 0.11 FTM791(321) OIT (190 o C) min. 33.15 ASTM D3895 Hydrogen generation (80°C/24hrs.) μl/g 0.012 Tensile strength (20 °C/70% RH) N 66 00 FOTP - 28 Coatmg stπp force (20 °C/70° o RH) N 4 10 FOTP - 178 Aging (100°C/240 hrs ) Pass see example 1 UV exposure (25°C/14 days) Pass Temperature exposure (240 c C/5 mins ) Pass Polypropylene compatibility (80°C/2 wks ) Pass see above OFT = Oxidative mduction time The results from the low temperature cone penetration, and the oil separation, volatile loss and oxidative mduction time experiments suggest that the operating range of this gel is -40 to +80 °C The tensile strength and coatmg stop force results suggested that there was no deteooration m the mechamcal strength of the fibres or degradation m the fibre coatmg after exposure to the gel The gel was found to be compatible with polypropylene as there was no weight gam m the immersed tube samples after aging EXAMPLE 5 This gel, formulated for cable flooding and interstitial filling applications and is a swellable water blockmg gel, was prepared in a similar manner to that descπbed m example 1 The formula for this gel is set out below The gel was subject to a number of physical tests, the results of which are summaπsed m Table 7 below Table 7 Physical Properties Property Value Test Method Density (20°C) g/ml 0 87 ASTM D 1475 Viscosity (200s 25°C) Pa s 7 00 Haake VT500 Cable dramage (80°C/24 hrs ) Pass EIA TIA-455-81A Cone Penetration (25°C) dmm 340 ASTM D937 Oil separation (80°C/24 hrs ) % wt 0 FTM791(321) OIT (190°C) mm >40 ASTM D3895 Hydrogen generation (80°C/24hrs) μl/g <0 02 Acid Value mgKOH/g <0 5 BS2000 Tensile strength (20°C/70% RH) N 66 00 FOTP - 28 Coatmg stnp force (20°C/70% RH) N 4 10 FOTP - 178 OIT = Oxidative mduction time The presence of unexpanded hollow micro spheres m the gel meant that the filler increased in volume by 1-10% on heatmg in the temperature range 95-140 °C Such heat can oπgmate from the extrusion head during manufacture of. for example, fibre optic cables The swellable nature of the gel can help eliminate voids m the cable created on shrinkage of the cable filler and ensure a watertight seal around the core The elimination of voids also reduces the likelihood of problems of attenuation associated with fibre optic cables The gel can also be used for filling beneath the metallic laminate where over-flooding with petroleum jelly type mateπal can prevent sealmg of the overlap whilst under-flooding may create a water path within the cable and lead to the problems of attenuation descπbed above It will readily be apparent that numerous modifications and alterations can readily be made to the compositions exemplified m the Examples without departmg from the pnnciples underlying the mvention and all such modifications and alterations are mtended to be embraced by this application

Claims: CLAIMS 1 A composition which compπses a dispersion of micro spheres m a gel compnsmg an oily base and an orgamc polymeπc gellmg agent 2 A composition which compπses a dispersion of micro spheres m a gel compnsmg an oily base and an orgamc polymeπc gellmg agent, the composition contaimng substantially no thixotropic agent other than the orgamc polymeπc gellmg agent A composition which compπses a dispersion of micro spheres m a gel compπsmg an oily base and a polymeπc gellmg agent wherem the polymeπc gellmg agent compπses, consists essentially of, or consists of a thermoplastic elastomer A composition which compπses a dispersion of micro spheres m a gel compπsmg an oily base and a polymenc gellmg agent wherem the polymeπc gellmg agent compnses, consists essentially of. or consists of a thermoplastic elastomer other than polystyrene- isoprene rubber A composition which compnses a dispersion of micro spheres m a gel compπsmg an oily base and a polymeπc gellmg agent wherem the polymeπc gellmg agent compπses, consists essentially of, or consists of a thermoplastic elastomer, excluding compositions contaimng polystyrene-isoprene rubber and an orgamc thickener A composition which compπses a dispersion of micro spheres m a gel compπsmg an oily base and a thermoplastic elastomer as a gellmg agent, the composition contaimng substantially no thixotropic agent m addition to the thermoplastic elastomer A gel composition compπsmg a dispersion of orgamc microspheres m a gel compπsmg an oily base and a thermoplastic elastomer, the gel contaimng substantially no thixotropic agent in addition to the thermoplastic elastomer and bemg substantially free from silica, for example fumed sihca A composition according to Claim 1 wherem the gel is substantially free of fumed sihca A composition accordmg to any one of claims 1 to 8 which is suitable for use as a cable filler A composition accordmg to any one of the precedmg claims herem the oily base compπses at least one oil selected from naphthemc or paraffimc processmg oil, mineral oil, synthetic oils such as a poly(cc -olefin) synthetic oil and sihcone oil A composition accordmg to any one of the precedmg claims wherem the oily base is present m an amount m the range from 1 to 99% by weight of the composition A composition accordmg to Claim 1 1 wherem the oily base is present m an amount in the range from 50 to 99% by weight of the composition, for example m the range 80- 99% by weight of the composition A composition according to any one of the precedmg claims wherem the polymeπc gellmg agent is a theonoplastic rubber A composition accordmg to any one of the precedmg claims wherem the polymeπc gellmg agent is present in an amount m the range 1-10% by weight of the composition, for example m the range 2-9% by weight of the composition, preferably m an amount m the range 3-8% by weight of the composition A composition accordmg to any one of the precedmg claims contammg one or more anti- oxidants A cable, such as a commumcations cable, contammg as a filler a composition as defined m any one of claims 1 to 15 A cable compπsmg a conductmg core suπounded by a sheath, a composition as defined m any one of claims 1 to 15 bemg disposed between the conducting core and the sheath A cable according to claim 16 or claim 17 wherem the conductmg core is an electπcal conductor or a light conductor A process for makmg a cable compπsmg a conductmg core and a sheath, the process compπsmg the step of extruding the cable sheath onto the conductmg core and interposing a composition as defined in any one of claims 1 to 14 between the conducting core and sheath during the extrusion step A process for prepaπng a composition as defined m any one of Claims 1 to 15, the process compπsmg (a) heatmg the oily base to a temperature m the range 110°C to 120°C, (b) add g the polymeric gellmg agent to the oily base and blendmg to form a mixture, (c) coolmg the mixture to a temperature of less than 90°C, (d) adding and blendmg m the micro spheres, and optionally (e) adding and blendmg m an anti-oxidant and/or (f) mamtammg the mixture under vacuum to remove entrapped gas A process for manufacturmg a composition accordmg to any one of Claims 1 to 15 which process compπses (I) blendmg at least one oil m a heating-blending tank, (u) heatmg the blended oils to 110-120°C m a stioed heating-blending tank, (in) addmg and blendmg the polymeπc gellmg agent to the oily base under high shear for no more than one hour after transfer of the oily base to a blending- coohng tank, allowing the temperature of the blend to πse to more than 120- 130°C, (IV) coolmg the blend to <90°C and transferring to a stioed mam reactor, (v) addmg and blendmg m an anti-oxidant package, (vi) addmg and blendmg the micro spheres, drawn to the reactor under vacuum or pumping, for at least two mmutes, (vn) mamtammg the vacuum for at least another 10 mmutes m order to effect removal of air bubbles pnor to release of the finished composition A composition substantially as descnbed herem with reference to the examples

Inventors: SOHAL MUKTIAR SINGH, SOHAL, MUKTIAR, SINGH
Applicants: SOHAL MUKTIAR SINGH, UNIGEL LTD, SOHAL, MUKTIAR, SINGH, UNIGEL LIMITED
Application year: 2001
Main classification: B01J13
IPC codes: B01J13, C08J9, C08K7, G02B6, H01B7