Fiber optic cable assembly for installation on a powerline conductor

1. A fiber optic cable comprising:

a plurality of optical fibers;

a core tube surrounding the plurality of optical fibers, wherein the core tube comprises a single-layer core or a dual-layer core tube;

a thixotropic gel filling an interstitial space among the plurality of optical fibers within the core tube, wherein the thixotropic gel increases a hoop strength applicable to the core tube;

an intermediate layer surrounding the core tube, wherein the intermediate layer comprises a plurality of linear elements contra-helically wrapped about the core tube to provide a predetermined tensile strength to the fiber optic cable without overcoming the hoop strength of the core tube and to manage cable length recovery from a tensile condition of the fiber optic cable; and

an outer layer surrounding the intermediate layer, wherein the outer layer comprises a combination of a moisture-cure cross-linked material and an activation catalyst, and wherein the outer layer is formed by masticating and extruding the combination onto the intermediate layer.

2. The fiber optic cable of claim 1 , wherein the plurality of optical fibers comprises a plurality of single-mode optical fibers.

3. The fiber optic cable of claim 1 , wherein the plurality of optical fibers comprise a plurality of multi-mode optical fibers.

4. The fiber optic cable of claim 1 , wherein an inner tube of the dual-layer core tube comprises a resin that prevents an oil of the thixotropic gel from contacting an outer tube of the dual-layer core tube.

5. The fiber optic cable of claim 1 , wherein the plurality of linear elements are impregnated with a swellable polymer.

6. The fiber optic cable of claim 1 , further comprising a plurality of swellable fibers that are aligned parallel to each other and adjacent the plurality of linear elements.

7. The fiber optic cable of claim 6 , wherein the plurality of swellable fibers are located under the intermediate layer.

8. The fiber optic cable of claim 6 , wherein the plurality of swellable fibers are located atop the intermediate layer.

9. The fiber optic cable of claim 1 , wherein the plurality of linear elements comprise a plurality of aramid fibers.

10. The fiber optic cable of claim 1 , wherein the plurality of linear elements comprise a plurality of oriented polymer fibers.

11. The fiber optic cable of claim 1 , wherein the plurality of linear elements comprise fiberglass.

12. The fiber optic cable of claim 1 , wherein the plurality of linear elements comprise a plurality of coated fiberglass yarns.

13. The fiber optic cable of claim 1 , wherein the moisture-cure cross-linked material comprises moisture-cure high-density polyethylene.

14. The fiber optic cable of claim 1 , wherein the outer layer further comprises a chemical animal repellant.

15. A method of assembling a fiber optic cable, comprising:

providing a plurality of optical fibers and a thixotropic gel within a core tube, wherein:

the core tube comprises a single-layer core tube or a dual-layer core tube,

the thixotropic gel fills an interstitial space among the plurality of optical fibers within the core tube, and

the thixotropic gel increases a hoop strength applicable to the core tube;

contra-helically wrapping a plurality of linear elements about the core tube to provide a predetermined tensile strength to the fiber optic cable without overcoming the hoop strength of the core tube and to manage cable length recovery from a tensile condition of the fiber optic cable, wherein the plurality of linear elements form an intermediate layer surrounding the core tube; and

masticating and extruding a combination of a moisture-cure cross-linked material and an activation catalyst onto the intermediate layer to form an outer layer that surrounds the intermediate layer.

16. The method of claim 15 , wherein the combination further comprises an animal repellant.

17. The method of claim 16 , wherein the combination further comprises at least one of low-density polyethylene pellets including the animal repellant or ethylene vinyl acetate pellets including the animal repellant.

18. The method of claim 15 , further comprising curing the combination after extruding the combination onto the intermediate layer.

19. The method of claim 18 , further comprising:

applying a wax to the outer layer;

winding the fiber optic cable into a circular bundle;

reshaping the circular bundle into a noncircular bundle; and

heating the noncircular bundle to reflow the wax.

20. A fiber optic cable comprising:

a core tube surrounding a plurality of optical fibers;

a thixotropic gel filling an interstitial space among the plurality of optical fibers within the core tube, wherein the thixotropic gel increases a hoop strength applicable to the core tube;

an intermediate layer comprising a plurality of fibers braided about the core tube to provide a predetermined tensile strength to the fiber optic cable without overcoming the hoop strength of the core tube and to manage cable length recovery from a tensile condition of the fiber optic cable, wherein the plurality of fibers are impregnated with a swellable polymer;

a ripcord positioned atop the intermediate layer; and

an outer layer surrounding the intermediate layer and the ripcord, wherein:

the outer layer comprises a moisture-cure cross-linked material, an activation catalyst, and a chemical animal repellant that are masticated and extruded onto the intermediate layer; and

the ripcord facilitates removal of a portion of the outer layer from the intermediate layer.