U.S. patent application number 14/455899 was filed with the patent office on 2014-11-27 for synthetic rope for powered blocks and methods for production.
This patent application is currently assigned to HAMPIDJAN HF. The applicant listed for this patent is Hjortur Erlendsson. Invention is credited to Hjortur Erlendsson.
Application Number | 20140345098 14/455899 |
Document ID | / |
Family ID | 51934412 |
Filed Date | 2014-11-27 |
United States Patent
Application |
20140345098 |
Kind Code |
A1 |
Erlendsson; Hjortur |
November 27, 2014 |
SYNTHETIC ROPE FOR POWERED BLOCKS AND METHODS FOR PRODUCTION
Abstract
Disclosed is a method for producing a high strength synthetic
strength member (7) containing rope (1) capable of being used with
powered blocks where such rope has lighter weight and similar or
greater strength than steel wire strength member containing ropes
used with powered blocks. Disclosed also is the product resulting
from such method. The product includes a synthetic strength member,
a first synthetic portion (9) and a second synthetic portion. The
first synthetic pillion is enclosed within the strength member and
the second synthetic portion is situated external the strength
member. At least a portion of the second synthetic portion also is
situated internal a sheath (8) formed about the strength member.
The second synthetic portion has a minimal of 8% at a temperature
of between negative 20 and negative 15.degree. C.
Inventors: |
Erlendsson; Hjortur;
(Kopavogur, IS) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Erlendsson; Hjortur |
Kopavogur |
|
IS |
|
|
Assignee: |
HAMPIDJAN HF
Reykjavik
IS
|
Family ID: |
51934412 |
Appl. No.: |
14/455899 |
Filed: |
August 9, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13393760 |
Mar 1, 2012 |
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14455899 |
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Current U.S.
Class: |
28/245 ;
87/7 |
Current CPC
Class: |
D07B 1/185 20130101;
D07B 2201/2066 20130101; D07B 2205/2096 20130101; D07B 2401/205
20130101; D07B 2205/2003 20130101; D07B 2201/2095 20130101; D07B
2205/2064 20130101; D07B 2207/4059 20130101; D07B 2201/2053
20130101; D07B 2205/2014 20130101; D04C 1/12 20130101; D07B 1/025
20130101; D07B 2201/2066 20130101; D07B 2201/102 20130101; D07B
2201/2048 20130101; D07B 2205/2064 20130101; D07B 2201/209
20130101; D07B 2201/2096 20130101; D07B 2201/1096 20130101; D07B
2205/2042 20130101; D07B 2207/405 20130101; D07B 2301/3591
20130101; D07B 2205/2014 20130101; D07B 2201/2067 20130101; D07B
2201/2053 20130101; D07B 7/165 20130101; D07B 2201/2074 20130101;
D07B 5/12 20130101; D07B 2201/2048 20130101; D07B 2207/405
20130101; D07B 2207/4059 20130101; D07B 2205/2042 20130101; D07B
2205/2003 20130101; D07B 2401/2055 20130101; D07B 2207/4068
20130101; D07B 2301/258 20130101; D07B 2501/2038 20130101; D07B
2801/10 20130101; D07B 2801/24 20130101; D07B 2801/10 20130101;
D07B 2801/60 20130101; D07B 2801/14 20130101; D07B 2801/10
20130101; D07B 2801/24 20130101; D07B 2801/60 20130101; D07B
2801/16 20130101; D07B 2801/24 20130101; D07B 2801/60 20130101;
D07B 2801/24 20130101; D07B 2501/2061 20130101; D07B 2201/2067
20130101; D07B 2205/2096 20130101; D07B 2207/4068 20130101 |
Class at
Publication: |
28/245 ;
87/7 |
International
Class: |
D07B 7/02 20060101
D07B007/02 |
Claims
1-50. (canceled)
51. A process for forming a mainly synthetic rope (1) formed of at
least a strength member (7), the process including steps of forming
the strength member (7) with a braided construction and from
filaments including filaments that are able to be creeped, the
process comprising steps of: a) first, applying tension to at least
the strength member (7); b) second, after applying tension to at
least the strength member, maintaining tension on at least the
strength member; c) subsequently, while maintaining tension on at
least the strength member, applying a heat to at least the strength
member; d) selecting a combination of the tension and the heat for
step (c) so as to cause creep of those filaments of the strength
member that are the filaments that are able to be creeped, e)
detecting a desired amount of elongation of at least the strength
member; and f) while maintaining tension on at least the strength
member, cooling the strength member.
52. The process of claim 51 further comprising steps of cooling the
strength member while selecting a sufficient tension for the step
of maintaining a tension on the strength member during the cooling
process so as to result in permanent elongation of the strength
member.
53. The process of claim 52 wherein the process further comprises
selecting for the desired amount of elongation of the strength
member an amount of elongation that results in the strength member
having a lesser diameter than it had prior to the strength member
being permanently elongated.
54. The process of claim 53 wherein the process further comprises
selecting for the desired amount of elongation of the strength
member an amount of elongation that results in the strength member
having a greater compactness than it had prior to the strength
member being permanently elongated.
55. The process of claim 52 further comprising steps of cooling the
strength member while selecting a sufficient tension for the step
of maintaining a sufficient tension on the strength member during
the cooling process so as to result in permanent elongation of
filaments forming the strength member.
56. The process of claim 53 further comprising steps of cooling the
strength member while selecting a sufficient tension for the step
of maintaining a sufficient tension on the strength member during
the cooling process so as to result in permanent elongation of
filaments forming the strength member.
57. The process of claim 54 further comprising steps of cooling the
strength member while selecting a sufficient tension for the step
of maintaining a sufficient tension on the strength member during
the cooling process so as to result in permanent elongation of
filaments forming the strength member.
58. The process of claim 51 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
59. The process of claim 52 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
60. The process of claim 53 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
61. The process of claim 54 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
62. The process of claim 55 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
63. The process of claim 56 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
64. The process of claim 57 wherein the process further comprises
using capstans turning at varying speeds to apply tension to the
strength member.
65. The process of claim 51 wherein the tension of steps (a) to (c)
is lesser than 50 percent of the ropes breaking strength measured
at room temperature.
66. The process of claim 52 wherein the tension of steps (a) to (c)
is lesser than 50 percent of the ropes breaking strength measured
at room temperature.
67. The process of claim 53 wherein the tension of steps (a) to (c)
is lesser than 50 percent of the ropes breaking strength measured
at room temperature.
68. The process of claim 52 further characterized by forming a
braided sheath (8) about the strength member.
69. The process of claim 68 further characterized by forming the
braided sheath (8) with a braid angle that is more acute than a
braid angle forming the strength member (7).
70. The process of claim 53 further characterized by forming a
braided sheath (8) about the strength member and by forming the
braided sheath (8) with a braid angle that is more acute than a
braid angle forming the strength member (7).
Description
TECHNICAL FIELD
[0001] The present disclosure relates generally to the technical
field of synthetic ropes and, more particularly, to a rope that
preferably is made from synthetic polymeric material, that has a
rather high breaking strength and that also has a rather light
weight compared to steel wire rope and that is capable of being
used with powered blocks, traction winches, powered winches,
powered drums, drum winches, powered capstans and in general any
powered turning element and/or rotating element capable of applying
force to a rope (hereinafter aggregately known as "powered
blocks"). Such synthetic ropes include but are not limited to tow
ropes, towing warps, trawl warps (also known as "trawlwarps"), deep
sea lowering and lifting ropes, powered block rigged mooring ropes,
powered block rigged oil derrick anchoring ropes used with blocks
and also with powered blocks, superwides and paravane lines used in
seismic surveillance including but not limited to used with towed
arrays, yachting ropes, rigging ropes for pleasure craft including
but not limited to sail craft, running rigging, powered block
rigged anchor ropes, drag lines, and the like.
BACKGROUND ART
[0002] Due to the high costs of raw materials needed to produce
synthetic high strength ropes such as ropes made from state of the
art synthetic materials including UHMWPE and others, it is
important to increase the both the longevity as well as the
strength that can be obtained from synthetic high strength ropes
for a given amount of material. In the case of increased longevity,
the increase in longevity is important in order to reduce
replacement costs. Additionally, the increase in longevity can
permit use of lowered diameter and thus lighter and less expensive
to deploy ropes as in the present state of the art larger than
necessary initial diameters are selected in order to provide for a
minimum desired longevity of the rope due to anticipated rates of
decrease in rope strength and ultimate longevity. In the case of
increased strength, the increase in strength is important both to
decrease costs of raw materials and production process, costs of
rigging equipment needed to carry, lift, stabilize and stably float
and/or otherwise sustain and support the weight of the ropes, as
well to decrease drag in water and drag in air of such ropes. In
the environment of winches, drums and traction winches, i.e.
powered blocks, it is especially important to make such ropes more
readily usable on such powered blocks. Furthermore, it is important
to increase the life expectancy of such ropes in order to obtain
the greatest economic advantage from a given investment in any such
rope.
[0003] While attempts and methods of adhering a steel wire rope's
strength member to a sheath surrounding a steel strength member
have failed in increasing the steel wire ropes strength, and
actually reduce the steel wire rope's strength for a given diameter
(a rope's strength necessarily measured in relation to its
diameter) such attempts and methods have succeeding in increasing
the longevity of certain steel wire ropes. However, in the case of
ropes formed with synthetic and/or mainly synthetic strength
members, all known attempts to increase the strength and/or the
longevity of synthetic ropes by adhering a sheath surrounding a
strength member to the synthetic and/or mainly synthetic strength
member have failed to increase either the strength of the rope or
its longevity, and in fact do the opposite. That is, known methods
of adhering a synthetic rope's strength member to a sheath
surrounding such strength member actually decrease both the
strength and longevity of the ropes. For this reason, such known
constructions increase not only the expense of the rope, but also
its diameter and thus associated drags in for example water, as
well as its weight and thus associated costs for structures
affixing, floating, sustaining or otherwise supporting such ropes.
As a consequence, it is contrary to the trend in the industry and
against the state of the art to adhere to a synthetic rope's
strength member a sheath surrounding such strength member.
[0004] As another consequence, it is accurate to state that it is
contrary to the trend in the industry and against the state of the
art to actually improve a rope's strength by adhering a sheath to
the ropes strength member, especially by adhering a sheath to a
synthetic and/or mainly synthetic ropes synthetic and/or mainly
synthetic strength member, and that such result would be surprising
to those skilled in the art.
[0005] In the present state of the art, when forming high strength
synthetic strength members for use in forming a high strength rope,
the strongest synthetic fiber available at a certain price point
and suitable for a certain environment of intended deployment is
used. It is well known that synthetic high strength ropes have a
drawback of being very expensive. Furthermore, synthetic high
strength ropes are prone to a much more rapid rate of degradation
than natural, e.g. wire ropes, and are quicker to experience
abrasion induced failure when used on powered blocks, whether in
protected environments or in high temperature and abrasive
environments, as opposed to when such synthetic high strength ropes
are used in static applications. However, due to their relatively
light weights and also due to their relative low diameters for a
given strength, and also due to their ability to not rust or
oxidize in air and humid environments at an appreciable rate
compared to metal fibre ropes, state of the art high strength
synthetic ropes, such as ropes made from Vectran.RTM., Zylon.RTM.
(i.e. PBO), Carbon fibers, Aramids and the like are highly
desirable in many applications where light weights and minimal
diameters are desired in order to minimize structural loads, to
enhance aesthetic appearance such as in pleasure yachting, to
minimize the costs of structures to which the ropes affix, and also
where low drags are desired such as in towed applications and
mooring applications, the relatively low diameters of such
synthetic high strength ropes providing for lowered drags compared
to other ropes. The present state of the art and the current trend
in the industry is that such ropes either do not include a sheath
about their synthetic strength member, or that if they do include a
sheath that no attempt is made and no construction is provided to
adhere the sheath and the strength member to one another. This is
because, as mentioned above, known constructions and methods for
adhering a synthetic strength member to a sheath surrounding such
strength member actually decrease the strength of as well as
decrease the longevity of known synthetic ropes, including
synthetic ropes for use with powered blocks.
[0006] Ropes having sheaths such as plastic sheaths surrounding a
strength member, and ropes having synthetic barriers including
adhesives and thermoplastics between a strength member and a sheath
have failed to be successfully used with powered blocks, whether
such ropes are synthetic or natural ropes, and the present state of
the art and the current trend in the industry is that natural as
well as synthetic strength members used with powered blocks have no
such type of sheath, as the cost of forming such sheaths has not
been proved to be of benefit. It is understood in the industry that
a sheath is not a primary strength bearing unit of a rope, whether
a natural or a synthetic rope, but rather that a strength member is
the primary strength bearing unit forming a rope. Nonetheless, due
to the advantages of lightness of weight that high strength
synthetic strength member ropes offer, attempts continue to be made
to successfully deploy into industry on a wide scale high strength
synthetic strength member ropes for use with powered blocks, such
attempts including forming a sheath formed of braided strands about
such high strength synthetic strength members in attempt to
increase the longevity and thus reduce the long term investment
associated with using high strength synthetic ropes. However, the
very high costs of such high strength synthetic strength member
containing ropes compared to natural high strength ropes, e.g. wire
ropes, and the fact that such high strength synthetic strength
member containing ropes when used with powered blocks experience
rather fast deterioration of their sheaths and ultimately of the
synthetic strength members, has resulted in the fact that today
only limited market acceptance has been gained for high strength
synthetic strength member containing ropes for use with powered
blocks. That is, known high strength synthetic strength member
containing ropes used with powered blocks are known for rather
quickly experiencing abrasion induced failure, and for experiencing
a rather rapid strength degradation prior to absolute failure for
their cost. Due to the extremely high cost of such ropes, their
premature failure and short life spans when used with powered
blocks, the adoption of high strength synthetic strength member
ropes for use with powered blocks has been limited. For example,
the vast majority of the world's trawlers even in highly developed
regions continue to use wire rope as trawl warps, despite the great
weight and safety concerns caused by such weight when the natural
high strength rope is stored on a trawl winch--i.e. vessel
instability, it being well known that the weight of such stored
wire trawling warps has often been implicated in vessel capsize.
Thus, a long felt need continues to exist in the industry for a
high strength synthetic strength member containing rope capable of
being used with powered blocks that has improved longevity,
including improved strength retention over time. Thus also, it can
be appreciated that a long felt need continues to exist in the
industry for a high strength synthetic strength member containing
rope capable of being used with powered blocks that has improved
strength.
[0007] Published Patent Cooperation Treaty (PCT) International
Publication Number WO 2004020732 A2, International Application
Number PCT/IS2003/000025 discloses a cable having a thermoplastic
core within a braided synthetic strength member. The cable is a
heat stretched cable exhibiting ultra compactness and is useful for
high tension powered block applications. In one embodiment,
disclosed is a cable wherein the material of the thermoplastic core
contacts both the synthetic strength member and a braided synthetic
sheath formed about the outside of the strength member. However,
this embodiment has failed to be commercially accepted for the
reasons taught above, i.e. due to the fact that the strength of the
cable is reduced by such construction.
[0008] In all embodiments, it is taught that the heat stretching
and compacting of the cable is accomplished either by
simultaneously heating and stretching with tension the combination
of the strength member, the thermoplastic core and a second sheath
formed about the thermoplastic core and also contained within the
strength member, the purpose of such second sheath being to prevent
uncontrolled flow of molten phase of the thermoplastic core during
processing of the rope, or by first applying the heat and
subsequently applying the tension. This cable has found more
commercial acceptance than any other synthetic rope for use with
high tension powered blocks, and is the only viable synthetic rope
in the known art for use with high tension powered blocks such as
trawler winches for purposes such as trawl warps, and this cable
and its taught manufacturing processes represent both the state of
the art as well as the trend in the industry.
DISCLOSURE
[0009] It is an object of the present disclosure to provide for a
high strength synthetic strength member containing rope for use
with powered blocks that addresses the above stated long felt need
in the industry.
[0010] It is an object of the present disclosure to provide for a
high strength synthetic strength member containing rope capable of
being used with powered blocks that exhibits improved strength.
[0011] It is another object of the present disclosure to provide
for a high strength synthetic strength member containing rope
capable of being used with powered blocks that exhibits improved
strength retention over time and thus improved longevity.
[0012] It is yet another object of the present disclosure to
provide for a high strength synthetic strength member containing
rope capable of being used with powered blocks that exhibits both
improved strength as well as improved strength retention over time
and improved longevity.
[0013] It is yet another object of the present disclosure to
provide for a high strength synthetic strength member containing
rope capable of being used with powered blocks and satisfying the
above stated objects of the present disclosure where such rope is
capable of being used in substitution of steel wire strength member
containing ropes for applications including but not limited to
trawl warps, anchoring lines, seismic lines, oil derrick anchoring
and mooring lines, tow ropes, towing warps, deep sea lowering and
lifting ropes, powered block rigged mooring ropes, powered block
rigged oil derrick anchoring ropes used with blocks and also with
powered blocks, superwides and paravane lines used in seismic
surveillance including but not limited to used with towed arrays,
yachting ropes, rigging ropes for pleasure craft including but not
limited to sail craft, running rigging, powered block rigged anchor
ropes, drag lines, climbing ropes, pulling lines and the like.
[0014] Disclosed is a method for producing a high strength
synthetic strength member containing rope capable of being used
with powered blocks where such rope has lighter weight and similar
or greater strength than steel wire strength member containing
ropes used with powered blocks. Disclosed also is the product
resulting from such method. Most broadly, the product includes a
synthetic strength member, a first synthetic portion and a second
synthetic portion, where the first synthetic portion is enclosed
within the strength member and/or mainly is enclosed within the
strength member and the second synthetic portion is situated
external the strength member and/or mainly is situated external the
strength member, at least a portion of the second synthetic portion
also being situated internal a sheath formed about the strength
member, the first and second synthetic portions having differing
elasticity values, the second synthetic portion having greater
elasticity than the first synthetic portion. Preferably, the
elasticity of the second synthetic portion is in a range of
elasticity values as taught herein as useful for an adhesive
substance capable of adhering the strength member to the sheath,
with a range of elasticity of from twenty percent (20%) to five
hundred fifty percent (550%) measured at any temperature, within
two (2) degrees Centigrade of zero (0) degrees Centigrade, being
preferred, such as preferably at zero degrees Centigrade.
[0015] In a most preferred embodiment, an additional synthetic
substance is situated and/or mainly situated about and between
fibres forming the strength member, the additional synthetic
substance capable of being an adhesive substance that adheres one
to another various fibres forming the strength member and also
preferably has an elasticity that is lesser than the elasticity of
the second synthetic portion.
[0016] Most broadly, the method for producing the high strength
synthetic rope capable of being used with powered blocks is
characterized by the steps of:
[0017] a) providing a core capable of supporting a hollow strength
member and capable of fitting within an internal cavity formed by
the hollow strength member, this core forming the first synthetic
portion;
[0018] b) forming a synthetic strength member about the core;
[0019] c) situating about the outside of the strength member a
substance capable of being, during at least one of its phases, a
substance capable of adhering a substance forming the strength
member to a substance forming a sheath, the sheath preferably being
a braided sheath formed of strands formed of synthetic fibres;
and
[0020] d) forming the sheath about the outside of both the strength
member and the substance capable of being, during at least one of
its phases, a substance capable of adhering the substance forming
the strength member to the substance forming the sheath, where the
substance capable of adhering the substance forming the strength
member to the substance forming the sheath has an elasticity that
is greater than the elasticity of the core, and that preferably is
in the range of elasticity values as taught herein as useful for an
adhesive substance capable of adhering the strength member to the
sheath, with a range of elasticity of from twenty percent (20%) to
five hundred fifty percent (550%) measured at any temperature,
within two (2) degrees Centigrade of zero (0) degrees Centigrade
being preferred, such as preferably at zero degrees Centigrade.
[0021] The substance capable of being, during at least one of its
phases, a substance capable of adhering a substance forming the
strength member to a substance forming the sheath, forms the second
synthetic portion of the rope of the present disclosure.
[0022] Most preferably, the method includes the additional step of
including about and between fibres forming the strength member a
third synthetic substance where such third synthetic substance is
capable of adhering one to another various fibres forming the
strength member, such third synthetic substance having an
elasticity that is lesser than the elasticity of the second
synthetic substance.
[0023] Due to the disclosed synthetic rope for use with powered
blocks light weight compared to steel wire cable coupled with its
improved strength, improved strength retention over time and
improved longevity, it possesses the advantages of being more
buoyant in water than steel wire cable while also being capable of
enduring the rigors of use in any of the mentioned applications of
use for a longer duration than steel wire cable.
[0024] Another advantage of the disclosed synthetic rope for
powered blocks is that it permits dramatically reduced
superstructures and associated costs for floating mooring andor
anchor lines needed to anchor oil derricks, especially deep water
oil derricks and other floating structures.
[0025] Yet another advantage of the disclosed synthetic rope for
powered blocks is that due to its increased strength less of the
rope is required and thus less weight is required to be stored on
for example trawler drums, and thus it lowers the center of
buoyancy of trawlers using the disclosed rope for trawl warps
thereby improving trawler safety.
[0026] Yet another advantage of the disclosed synthetic rope for
powered blocks is that due to its increased strength less of the
rope is required and thus it has a lowered diameter per application
requirement, thereby concurrently reducing drags in water and fuel
consumption costs associated with pertinent applications including
but not limited to trawl warps, superwides and paravane lines,
seismic lines anchor lines, deep water oil derrick mooting andor
anchoring lines, drag lines and others as a result of the increased
strength of the disclosed rope.
[0027] Yet another advantage of the disclosed synthetic rope for
powered blocks is that due to its increased strength less of the
rope is required and thus it has a lowered diameter per application
requirement, thereby reducing costs to produce and acquire the
rope.
[0028] Possessing the preceding advantages, the disclosed synthetic
rope for powered blocks answers needs long felt in the
industry.
[0029] It can readily be appreciated that these and other features,
objects and advantages are able to be understood or apparent to
those of ordinary skill in the art from the following detailed
description of the preferred embodiment as illustrated in the
various drawing figures.
BRIEF DESCRIPTION OF DRAWINGS
[0030] FIG. 1 is a plan view of a portion of a rope of the present
disclosure.
[0031] FIG. 2 is a view of a cross section of the rope of the
present disclosure taken along line A-A FIG. 1.
[0032] FIG. 3 is an expanded detail view of a portion of the cross
section of the rope of the present disclosure shown in FIG. 2 that
is indicated by reference character B. The expanded detailed view
includes a braided sheath of the rope of the present disclosure, a
portion of the strength member of the rope of the present
disclosure where such portion of the strength member is proximal
the braided sheath, as well as associated structures.
[0033] Figure legend: 1--Synthetic Rope of the Present Disclosure
[0034] 2--Lead Core [0035] 3--Shaped Supportive (Thermoplastic)
Core [0036] 5--Flow Shield Sheath [0037] 7--Strength Member [0038]
9--Elastic Adhesive Substance Layer [0039] 10--Coverbraid Strands
[0040] 13--Elastic Adhesive Substance Gap Filling Surface Layer
BEST MODE FOR CARRYING OUT THE DISCLOSURE
[0041] FIG. 2 and FIG. 3 illustrate essential constructional
components of one of the most preferred embodiments for use with
high tension powered blocks of the rope for powered blocks and
winches of the present disclosure that is identified by the general
reference character 1. FIG. 2 depicts a preferably thermoplastic
shaped supportive core 3 enclosing a lead core 2, the shaped
supportive core 3 being enveloped within a flow shield sheath 5.
Strength member 7 encloses the combination of the shaped supportive
core 3, its enveloping flow shield sheath 5 and its lead core 2.
Sheath 8 preferably is of a braided construction and is adhered to
strength member 7 by elastic adhesive substance layer 9, that
preferably is formed of a settable adhesive substance. Preferably
braided sheath 8 is formed of multiple coverbraid strands 10 by use
of a braiding machine, the coverbraid strands 10 preferably are of
a laid construction. Optionally, and preferably, as shown in more
easily visible detail in FIG. 3, elastic adhesive substance gap
filling surface layer 13 fills in depressions on the surface of
rope 1 formed in between adjacent coverbraid strands 10. Lead core
2 is optional, and is preferred for trawl warp applications and in
the case of certain other applications, but not necessarily in the
case of anchor lines and deep water oil derrick mooring and/or
anchoring lines or yachting lines, although in some cases it may be
used in such applications.
[0042] Shaped supportive core 3 also defines the first synthetic
portion of the rope of the present disclosure mentioned above, and
elastic adhesive substance layer 9 also defines the second
synthetic portion of the rope of the present disclosure as
mentioned above.
[0043] The present disclosure is based upon the surprising and
shocking discovery that both the strength, the strength retention
over time of as well as the longevity of a synthetic high strength
rope can be materially increased by adhering to the outside surface
of a synthetic strength member a sheath and preferably a tightly
braided sheath by use of an adhesive substance exhibiting when in
its final, set phase an elasticity of greater than eight percent
(8%) when the final set phase of the adhesive substance is measured
at any temperature in a temperature range including from negative
twenty (-20) degrees Centigrade to negative fifteen (-15) degrees
Centigrade. Such result is shocking and surprising because it is
contrary to the trend in the industry and against the state of the
art. An adhesive substance exhibiting the greater than 8% (eight
percent) elasticity at such temperature range also provides for a
rope exhibiting the improved strength, improved strength retention
over time as well as exhibiting the improved longevity at higher
temperatures, and at lower temperatures, even temperatures
exceeding seventy (seventy) degrees Centigrade and also even
temperatures lower than negative twenty (-20) degrees
Centigrade.
[0044] In a preferred embodiment of the present disclosure, the
adhesive substance exhibits when in its final, set phase an
elasticity preferably of greater than ten point one percent (10.1%)
when the final set phase of the adhesive substance is measured at a
temperature range including from negative fifteen (-15) degrees
Centigrade to negative five (5) degrees Centigrade. An adhesive
substance exhibiting the greater than 10.1% (ten point one percent)
elasticity at such temperature range also provides for a rope
exhibiting the improved strength, improved strength retention over
time as well as exhibiting the improved longevity at higher
temperatures, and at lower temperatures, even temperatures
exceeding seventy (seventy) degrees Centigrade and also even
temperatures lower than negative twenty (-25) degrees Centigrade.
In an even yet more preferred embodiment the elasticity is
preferably at least twenty percent (20%) when measured at any
temperature within the above stated temperature range of from
negative fifteen (45) degrees Centigrade to negative five (-5)
degrees Centigrade, and even more preferably at least fifty percent
(50%) at such temperature range, yet more preferably at least
eighty percent (80%) at such temperature range, and yet even more
preferably at least one hundred percent (100%) at such temperature
range and where the adhesive substance also is capable of
exhibiting an elasticity of greater than twenty percent (20%) at
temperatures in a range of from room temperature (i.e. twenty-five
degrees Centigrade) up to and exceeding forty (40) degrees
Centigrade, with an elasticity measured at room temperature of
fifty-two percent (52%) to five hundred fifty percent (550%) being
preferred and with an elasticity of from one hundred percent (100%)
to five hundred fifty percent (550%) or even greater when measured
at room temperature being most preferred.
[0045] A preferred adhesive substance is one that contains an
elastomer or elastomer like substance, and/or an elastomer
containing substance, such as a solid elastomer-like polyurethane
based upon two, three or more component isocyanate polymer blends
and especially with additives and curatives. As taught in further
detail herein, the rope of the present disclosure preferably has
its primary strength member formed of UHMWPE and/or LCP and/or PBO.
An most preferred adhesive substance for adhering the strength
member to the sheath is an adhesive substance having at a
temperature that is within two (2) degrees of zero (0) degrees
Centigrade a minimal elasticity of greater than 20%, preferably of
greater than 50%, even more preferably of greater than 100%,
greater than 200%, greater than 300%, greater than 400% and greater
than 500%. In general, the greater the elasticity of the adhesive
substance over and above 20% at such temperature range, the greater
the longevity of the disclosed rope.
[0046] Other examples of suitable adhesive substances include
silicone, including pure (100%) silicone, as well as a substance
that can be made by combining substances known in the industry as
"hot melts" with sufficient elastomer and/or elastomeric substances
so as to result in a highly elastic hot melt type substance
exhibiting the above taught elasticity values at the above taught
temperature ranges.
[0047] For purposes of the present disclosure, a rope and/or a
portion of a rope is considered to be at the above taught
temperature ranges, or at a certain temperature range and an
elastic substance is considered to be at the above taught
temperatures and/or temperature range when such rope and/or elastic
substance has been continuously exposed to such temperature range
for at least 24 hours. For example, continuously exposed to a
temperature of from negative fifteen (-15) degrees Centigrade to
negative twenty (-20) degrees Centigrade for a period of time that
is at least 24 hours, and when the elastic substance being tested
for elasticity, rope and/or portion of rope being tested for its
elastic substances elasticity actually is at such temperature
range.
[0048] As taught supra, a rope having a strength member, and
preferably a synthetic strength member, adhered to a sheath and
preferably to a synthetic sheath by use of an elastic material
exhibiting the above taught elasticity at the above taught
temperatures is surprisingly and shockingly able to exhibit both
improved strength, improved strength retention over time as well as
improved longevity, including improved durability, at a wide range
of temperatures including temperatures from but not limited to even
temperatures exceeding seventy (seventy) degrees Centigrade and
also even temperatures lower than negative twenty (-20) degrees
Centigrade, depending largely upon the ability of filaments forming
synthetic portions of the rope of the instant disclosure to
tolerate a certain temperature.
[0049] In order to form the rope of the present disclosure:
[0050] In another embodiment a rope of the present disclosure is
able to be formed by situating upon the outside surface of a
strength member a film or other coating of an adhesive substance
having an elasticity preferably of at least 20% when measured at a
temperature range of including but not limited to from at least
zero degrees Centigrade to at least ten degrees Centigrade,
subsequently tightly braiding a braided sheath (including braided
cover) about the combination of the strength member and the film or
other coating of such adhesive substance, then causing and/or
permitting the adhesive substance to set (including cure).
[0051] In yet another embodiment a rope of the present disclosure
is able to be formed by situating upon the outside surface of a
strength member a braided, laid and/or wrapped layer of filaments
formed of a substance that is itself formed of a combination of hot
melt and sufficient elastomer and/or elastomeric substance so as to
permit, when elastomer containing hot melt substance is in a set
phase, the elasticity properties at the temperature ranges as
taught herein. In such embodiment of the present disclosure: first
a strength member is formed; then the filaments are situated upon
the outside of the strength member; then the sheath is formed about
the combination of the filaments and the strength member; then the
combination of the strength member, filaments and sheath are
subjected to a predetermined tension and temperature per the fifth
and sixth steps described supra for forming a rope of the present
disclosure according to the presently most preferred manufacture
method.
[0052] To further describe such embodiment: preferably a settable
adhesive substance is situated upon the outside surface of the
strength member, then a braided sheath is tightly braided about the
combination of the strength member and the settable adhesive
substance, then the settable adhesive substance is allowed to set
(including cure). In forming the rope of the present disclosure by
the method of this embodiment, preferably the settable adhesive
substance is situated upon the outside surface of the strength
member in such a fashion that and/or under conditions that preclude
the adhesive substance to set until at least that portion of the
sheath corresponding to any particular portion of the combination
of the strength member and the settable adhesive substance has
already been formed about the combination of the strength member
and the film or other coating of settable adhesive substance. In
other words, preferably the settable adhesive substance and/or the
conditions under which it is situated upon the outside surface of
the strength member, such as temperature, is/are selected so that
the settable adhesive substance sets and/or completely sets only
after the sheath has been formed about the outside surface of the
strength member, causing the sheath to adhere to the strength
member.
[0053] To form the rope of the present disclosure by another
embodiment of the present disclosure, an adhesive substance
including but not limited to either an already set adhesive
substance applied to the outside surface of the strength member as
powder, a fluid permitted to set, a tape or other wrapping is
caused to set prior to forming a sheath about the strength member,
or a settable adhesive substance that sets after the sheath is
formed about the strength member is/are situated upon the outside
surface of the strength member. Next, a braided sheath is tightly
braided about the outside surface of the strength member using
known methods and preferably from filaments formed and/or mainly
formed of the same material as filaments forming the strength
member. Then, the combination of the strength member, the adhesive
substance situated upon the outside surface of the strength member
and the preferably braided sheath formed about the combination of
the strength member and the adhesive substance situated on the
outside surface of the strength member are heated and/or exposed to
radiation, such as microwave radiation, and/or exposed to another
catalyst that causes the adhesive substance to undergo a phase
change, especially from solid to a liquid state, or from an
non-adhesive to an adhesive state, and then the adhesive substance
is caused to set, thereby adhering the strength member to the
sheath by the adhesive substance, the adhesive substance selected
so as to have the elasticity properties for a preferred adhesive
substance for practicing the instant disclosure as disclosed
herein.
[0054] Thus, in forming a rope of the present disclosure, a
synthetic rope is formed of a strength member and a braided sheath,
the strength member and the braided sheath both formed of synthetic
material, the synthetic rope having:
[0055] a synthetic substance filling out void spaces between the
strength member and the braided sheath and causing adherence of the
strength member to the braided sheath, where the synthetic
substance exhibits when in a set phase and when at a temperature
of:
[0056] a) between negative twenty and negative fifteen degrees
Centigrade a minimal elasticity of greater than 8%;
[0057] b) between negative fifteen and negative five degrees
Centigrade a minimal elasticity of greater than 10.1%; and
[0058] c) between negative fifteen and zero degrees Centigrade a
minimal elasticity of greater than 20%.
[0059] Furthermore, other elasticity values exhibited at other
temperatures, as taught herein, are useful for the synthetic
substance that causes adherence of the strength member to the
braided sheath.
[0060] Importantly, it is surprisingly and shockingly discovered
that to maximize both longevity as well as strength of the rope of
the present disclosure the synthetic strength member preferably
includes a chemical agent contacting the filaments forming the
strength member and/or being situated between filaments forming the
strength member and/or also including being situated upon the
outside surface of the strength member where such chemical agent
has a lower elasticity than the elasticity selected for the
adhesive substance that adheres a braided sheath to the outside
surface of the strength member (for the purposes of the present
disclosure, comparative elasticity values are measured at
temperature that is between negative zero degrees Centigrade and 10
degrees Centigrade). Such chemical agent may itself be an adhesive
agent. The settable adhesive substance preferably is situated upon
the outside surface of the strength member as a liquid or as a
semi-liquid, the terms "liquid" and "semi-liquid" as used in the
present disclosure both also known as "in a flowable state". This
includes that the settable adhesive substance may also be situated
around, about, so as to envelop or so as to be directly upon the
strength member including a strength member having additional
chemicals including additional adhesives upon and in between its
filaments and/or any other chemical or mechanical barrier upon its
outside surface and/or any adhesive substance or other substance
upon its outside surface to which the settable adhesive is able to
adhere. The braided sheath is then formed about the combination of
the strength member and the coating while the substance forming the
coating is still liquid and/or semi-liquid (including "flowable").
The set time, also known as the lag time, within which the settable
adhesive substance shall set is selected so that during the process
of braiding the braided sheath about the strength member the
strands forming the braided sheath are adhered to the strength
member. Void spaces normally between the strength member and the
braided sheath are filled by the settable adhesive substance, and
in some preferred embodiments the thickness of the coating, the
braiding angle as well as the lag time of the settable adhesive
substance are selected so that the settable adhesive substance
first is situated upon the outside surface of the strength member,
then the braided sheath is braided about the strength member
causing the settable adhesive substance both to occupy void spaces
between the braided sheath and the strength member as well as to
flow between the strands of the braided sheath to the outside
surface of the braided sheath, especially during the convergence of
such strands at or about the braid point, and remain on the outside
surface of the braided sheath. In this case, the method of the
present disclosure includes smoothing the settable adhesive
substance on and about the outside surface of the braided sheath so
that the settable adhesive substance acquires a smooth surface and
preferably a generally aesthetically attractive surface.
[0061] However, in this embodiment, the amount of the settable
adhesive substance that is able to flow between the strands is
largely related to the viscosity selected for the settable adhesive
substance. When a relatively low viscosity is selected, the
settable adhesive substance is able to more readily flow between
the strands of the braided sheath. One of ordinary skill in the art
having read the present disclosure shall by experimentation be able
to readily determine the ideal viscosity for any particular
settable adhesive substance, and such experimentally determined
values for a viscosity for any particular settable adhesive
substance is intended to be encompassed within the scope of the
teachings of the present disclosure. When a viscosity is selected
for the settable adhesive substance that precludes sufficient of
such settable adhesive substance to flow between the converging
strands of the braided sheath so as to result in a pre-determined
amount of the settable adhesive substance becoming situated upon
the outside surface of the braided sheath, an additional amount of
the settable adhesive substance may be situated directly upon the
outside surface of the braided sheath. Such settable adhesive
substance may be situated directly upon the outside surface of the
braided sheath by:
[0062] a) first passing the rope of the present disclosure with the
braided sheath already formed upon the strength member through a
bath of a selected settable adhesive substance, and then
either:
[0063] i) allowing such settable adhesive substance to dry, as is
suitable when the viscosity of the settable adhesive substance is
sufficiently high so as to allow the settable adhesive substance to
acquire an even and/or uniform distribution on and about the
outside surface of the braided sheath without further manipulation;
or
[0064] ii) when a relatively high viscosity is selected for the
settable adhesive substance, it is preferred to pass the rope
having been bathed in the selected settable adhesive substance
through a die that is designed, shaped and configured so as to
smooth the settable adhesive substance into a desired shape upon
the outside surface of the rope of the present disclosure,
preferably a circular cross sectional shape, and including into a
desired thickness.
[0065] Preferably, when the settable adhesive substance is situated
upon the outside surface of the braided sheath, the thickness of
the layer of the settable adhesive substance on and about the
outside surface of the braided sheath is such as to occupy
depressions (i.e. valleys) between the strands of the braided
sheath, while either not covering, or while lightly covering high
points (i.e. peaks) formed by the strands of the braided sheath. In
one embodiment, such high points, i.e. peaks, are visible, while
the valleys are filled with the settable adhesive substance, as is
accomplished by the fact that after some initial wear and surface
abrasion any settable adhesive substance present on the peaks is
rubbed off, leaving the settable adhesive substance that is located
in the valleys. During use, as the rope of the present disclosure
is bend over a radius, the compressed side of the bent rope
compresses the valley walls, whereby the portion of settable
adhesive substance within the valley walls is partially bulged
outward where it is able to grip and provide additional traction to
the surface upon and about which the rope is being bent.
[0066] Importantly, surprisingly, shockingly and contrary to the
state of the art and the trend in the industry, in order to obtain
both maximal strength as well as maximal strength over time (i.e.
longevity) from the rope of the instant disclosure, the strength
member is formed of filaments and/or includes filaments that are
able to be creeped. For example, filaments are selected that are
able to be permanently elongated upon being heated to a temperature
approaching or at the phase change temperature of a chemical mainly
forming the filaments. Surprisingly, shockingly and contrary to the
state of the art that is to employ maximally strong filaments such
as Vectran.RTM., Zylon.RTM. and others when forming high strength
ropes, it has been found that filaments having a lesser strength
than such maximally strong filaments, but able to be creeped as
taught above, are highly preferably for forming a maximally strong
rope of the present disclosure. In fact, surprisingly, shockingly
and contrary to the state of the art, a rope of the instant
disclosure formed of filaments that are able to be creeped as
taught herein, for example filaments formed of UHMWPE, is stronger
than a rope formed of stronger and coincidentally more expensive
filaments that are not able to be creeped, whether such rope formed
of stronger and coincidentally more expensive filaments not able to
be creeped is formed by known methods and constructions or by the
method and construction of the present disclosure.
Preferred Fabrication Methods
[0067] There are two preferred embodiments of the present
disclosure: one is a rope of the present disclosure for use in
applications where the rope of the present disclosure is subject to
storage under high compressive pressure, such as when used with
high tension winches and drums, such as when used as a trawler's
warp; another is where the rope of the present disclosure is not
subject to storage under high compressive pressure, such as is
common in many yachting applications.
[0068] In forming a preferred embodiment of the present disclosure
for use in applications where the rope of the present disclosure is
subject to storage under high compressive pressure:
[0069] First is provided a strength member formed of synthetic
fibres including polyethylene, especially HMWPE, UHMWPE and Liquid
Crystal Polymer (LCP). The strength member may be parallel laid,
laid (including twisted) or braided. A braided strength member
having several strands formed of twisted (laid) filaments is the
preferred embodiment. For example a braided strength member having
a minimum of eight plates, preferably ten strands, more preferably
twelve strands, yet more preferably 14 strand and yet more
preferably from 16 strands to 108 strands or even more as the
diameter of the rope requires, is preferred. Any conventional
construction type for a braided strength member may be used.
However, it is highly preferably and important for a preferred
embodiment of the instant disclosure that a braided strength member
is selected that has a thermoplastic core shaped so as to support
the natural interior shape of the braided strength member under
tension approaching breaking strength of the strength member.
Preferably, for a strength member is provided a braided strength
member where the filaments forming the strength member have been
creeped after the filaments have been braided into the strength
member, rather than prior to braiding the filaments into the
strength member, and where the resultant strength member is unable
to elongate greater than 5% before reaching break point when
measured at a original tension of 1000 Kg, and preferably so that
the resultant strength member is unable to elongate greater than 4%
before reaching break point when measured at a original tension of
1000 Kg, and yet more preferably is unable to elongate more than
3.6% before reaching break point when measured at a original
tension of 1000 Kg.
[0070] In forming a strength member for the preferred form of the
instant disclosure the following step are employed:
[0071] First; filaments are selected that are able to be creeped as
taught above and herein.
[0072] Second; a thermoplastic linear element is provided that is
formed with a thermoplastic that shall be in a liquid state but
more preferably that shall be semi-liquid, i.e. in a molten phase
when such thermoplastic is at a temperature that either is:
[0073] a) a temperature that is slightly below, say one, two,
three, four, five, six, or seven degrees Centigrade below a
temperature at which the selected filaments experience a phase
change; or
[0074] b) a temperature that is a temperature at which the selected
filaments experience a phase change.
[0075] The thermoplastic linear element is preferably a rod formed
of thermoplastic (the term "formed of thermoplastic" is understood
to include being formed of a sufficient quotient of thermoplastic
so as to permit the linear element to experience the semi-liquid,
i.e. molten phase during the circumstances taught supra and herein,
even though other substances might be included with the
thermoplastic, or even lead or other metal or heavy plastic might
be included in linear arrangement within the center of the
thermoplastic linear element that preferably is a rod, so as to
increase weight in water of the final product rope of the present
disclosure).
[0076] Third; a tightly woven braided flow-shield sheath is braided
around the thermoplastic rod. Filaments are selected to form the
flow-shield sheath that are not made either liquid or semi-liquid
at a temperature selected to either or both creep the filaments or
change the phase of either the filaments or the thermoplastic rod,
but rather that have a much higher softening point. Polyester is
suitable.
[0077] Fourth; the selected filaments are braided around the linear
element formed of a thermoplastic and its flow-shield sheath, such
as a thermoplastic rod surrounded by a flow-shield sheath, so as to
form a braided strength member including a thermoplastic core
surrounded by a flow-shield sheath.
[0078] Fifth; the braided strength member having the thermoplastic
rod surrounded by the flow-shield sheath as its core is then
subject first to tension and secondly to heat, while maintaining
the tension, in such a fashion and under such conditions that the
filaments forming the braided strength member either reach their
phase change temperature or approach sufficiently closely to their
phase change temperature so as to permit creeping of the filaments.
I.e. so as to permit permanently elongating both the filaments
forming the strength member, as well so as to permit permanently
elongating the strength member itself. A thermoplastic is selected
to form the thermoplastic core that shall preferably become
semi-liquid, i.e. molten, at the temperature used to permanently
elongate the filaments and braided strength member formed of the
filaments. The flow shield-sheath mainly or entirely stops the
phase changed thermoplastic core from exiting the flow-shield
sheath. That is, the majority of the thermoplastic core is unable
to exit the flow-shield sheath even when the thermoplastic core is
either liquid or semi-liquid, i.e. molten, despite enormous
constrictive and compressive forces applied to the phase changed
thermoplastic core as a result of the high tensions applied to the
strength member, such high tensions able to permanently elongate
the strength member under the conditions taught supra and
herein.
[0079] Applying the tension before applying the heat while then
maintaining the tension while the heat is being applied is, in
combination, contrary to the trend in the industry and against the
state of the art. A preferred tension to be used in the disclosed
processes for forming the disclosed rope is about three percent
(3%) to about fifteen percent (15%) of the break strength of the
strength member when such break strength is measured at room
temperature, with about three percent (3%) to about seven percent
(7) being preferred, and with less than fifty percent (50%) being
most important.
[0080] Importantly, the tension applied to the strength member, and
thus necessarily also applied to the filaments forming the strength
member, preferably is a static tension and/or a generally static
tension and/or a very slowly fluctuating tension. After applying a
predetermined tension (including approximately a predetermined
tension), and while under such predetermined tension simultaneously
the strength member, its filaments, and its thermoplastic core are
heated to a predetermined temperature and/or to approximately a
predetermined temperature as taught above and herein, with a
minimum temperature of eighty (80) degrees Centigrade being most
preferred, and temperatures that approach the phase change
temperature of whatever filament in the strength member has a
lowest phase change temperature being highly useful. The use of a
long oven having many capstans able to accommodate a very long
length of the strength member and turning at varying speeds and/or
rates of rotation so as to maintain the tension on differing
portions of the strength member located between different capstans,
and thus by extension on the filaments forming the strength member
as well as on the thermoplastic core also forming the strength
member is highly useful, especially for permitting an endless flow
production process.
[0081] Sixth; when the filaments and thus by extension the braided
strength member have been elongated to a predetermined amount so as
to permit a strength member having the properties described above
and herein, and especially having an elongation to break point
within the range of values as taught above and herein, and also the
thermoplastic core has been elongated, the elongated filaments, the
now elongated strength member formed of the elongated filaments and
its elongated thermoplastic core are cooled while sufficient
tension is maintained and applied to the strength member and thus
by extension to its filaments and to its thermoplastic core during
the cooling process so that all such components are cooled to their
respective solid states while under a tension that results in the
cooled filaments as well as the cooled strength member having been
permanently elongated so as to cause the strength member:
[0082] a) to acquire a lower elongation than it had prior to its
having been permanently elongated;
[0083] b) to acquire a substantially lesser diameter and a greater
compactness than it had prior to its having been permanently
elongated;
[0084] c) to acquire to its thermoplastic content core a permanent
solid shape that supports the interior cavity of the permanently
elongated strength member in such a fashion that the filaments and
braid strands forming the strength member are sufficiently less
able to move relative to one another in a direction perpendicular
to the long dimension of the permanently elongated strength member
in comparison to prior to the strength member having been
permanently elongated so as to reduce filament to filament abrasive
wear, and also so as to preclude crushing of the rope, especially
under high compressive forces such as occurs during winding and
storage on a high tension drum, the necessary tension to achieve
such result for any particular filament type able to be
experimentally determined by one of ordinary skill in the art after
having read the present disclosure; and also
[0085] d) to acquire a break point that is within the range of
values of elongation to break point as taught above and herein.
[0086] This cooling also is best accomplished and undertaken using
capstans turning at varying speeds so as to maintain a tension on
the elongated strength member and its components during the entire
cooling process and period that precludes their shortening, so that
the final cooled strength member has the values of elongation to
break point as taught above and herein for a most preferred
embodiment of the instant disclosure, and also the other properties
taught as above and herein, as also is accomplishable in an endless
flow production method.
[0087] In order to form a rope of the instant disclosure that is
not useful for applications requiring tolerating high compressive
pressures, such as applications not including a trawler's warp, and
other applications not including storage of the rope of the present
disclosure on high tension drums and winches, the step of forming
the thermoplastic rod with its flow-shield sheath is omitted, and
the subsequent steps are carried out the same as taught above and
herein except that the thermoplastic rod and its flow-shield sheath
are not present nor need their properties be considered.
[0088] Seventh; while the flowable settable adhesive substance is
still liquid and/or semi-liquid (including "flowable") it is
situated upon the outside surface of the preferably permanently
elongated strength member, then a preferably braided sheath is
formed about the combination of the permanently elongated strength
member and the flowable settable adhesive substance. The
temperature of the settable adhesive substance at the time when it
contacts the strength member preferably is less than eighty (80)
degrees Centigrade, and also preferably less than 117% Centigrade,
and at a temperature that shall not damage the synthetic filaments
contacting the adhesive substance. In other words, the settable
adhesive substance is situated upon the strength member at
temperature that is lower than a phase change temperature of fibres
forming the strength member, and preferably also lower than a phase
change temperature of fibres forming a braided sheath to be formed
about the strength member as taught in subsequent steps of the
disclosed method. Preferably, the strength member is under a
tension that increases the temperature that filaments forming the
strength member are able to tolerate when situating upon the
strength member the gettable adhesive substance, and similarly the
braids of the braided sheath are also under such a tension. The
braid point, braid tension, thickness of the coating, viscosity of
the settable substance and lag time can be selected so that no or
minimal flow of the flowable settable adhesive substance to the
outside surface of the braided sheath occurs. Or, the braid point,
braid tension, thickness of the coating and lag time may be
selected so that a flow of sufficient volume of the settable
adhesive substance to the outside surface of the braided sheath
occurs so as to permit smoothing that portion of the settable
adhesive substance that flowed to the outside surface of the
braided sheath into a smooth coating about the braided sheath. A
lag time, also known as a "set time", of at least 15 seconds is
preferred, with at least one minute being more preferred, with at
least 2 minutes being yet more preferred, with at least 3 minutes
being even yet more preferred, with at least 4 minutes being yet
again more preferred, with at least 5 minutes being even more
preferred, with at least 6 minutes, at least 7 minutes, at least 8
minutes, at least 9 minutes, at least 10 minutes, at least 11
minutes, at least 12 minutes, at least 13 minutes, and least 14
minutes being most preferred, and with up to one hour or even more
being useful. Thus, the method includes selecting for a lag time
any of the above mentioned preferred lag times, with at least 15
seconds being the minimal preferred lag time.
[0089] In order to prepare the outside of the strength member and
possibly as well the inside of the strands converging to form the
braided sheath for adhesion via the adhesive substance, electricity
preferably is applied to the surface of preferably the strength
member, and possibly also to the strands forming the braided
sheath, at a stage in the production process that is immediately
before the deposition of the settable adhesive substance onto the
surface of the strength member. This can be accomplished by Corona
treatment (e.g. air plasma method and treatment), or by Atmospheric
Plasma method and treatment, Flame Plasma method and treatment or
Chemical Plasma method and treatment. A brush--the term "brush" in
this instance as used in electrical energy applications, having a
circular dimension through which passes at least the strength
member is preferred for utilization of the Corona treatment. While
it has been described that this production method embodiment is
used when employing a flowable, settable adhesive substance, it
also can be used when employing production methods including
situating upon the outside surface of the strength member solid,
including powder, phase changeable substances capable of causing
adherence of the strength member to the sheath.
[0090] A presently preferred method includes using a polyurethane
blending machine (e.g. a mixing machine) having an injection head
constructed, designed and configured to situate the desired coating
of the flowable adhesive substance about the outside surface of the
braided sheath. This may be done by configuring the injection head
either to spray, extrude a bead, or pour a stream. Then, the
flowable adhesive substance may be situated onto the outside
surface of the strength member by spraying the settable adhesive
substance onto the strength member, or alternatively by passing the
strength member through a bath of such substance, or again
alternatively by pouring such substance directly onto the strength
member. If direct spraying or pouring is selected, the injection
head is positioned adjacent to the outside surface of a length of
the strength member. The strength member is fed out from a pay out
spool while simultaneously being taken up on a take up spool. The
braided sheath is formed about the strength member as described
using usual methods for forming a braided sheath about a strength
member. Preferably, the braid point is immediately behind (i.e.
downstream of) either the application point of the flowable
adhesive substance onto the strength member's outside surface, or
is immediately downstream of a die that itself is immediately
downstream of the application point of the flowable adhesive
substance onto the strength member's outside surface, so that the
strands of the braided sheath are pressed into the flowable
adhesive substance and pressed onto the outside surface of the
strength member prior to and preferably immediately prior to the
flowable adhesive substance setting (i.e. solidifying), and
becoming solid. The flowable adhesive substance in its set, and
especially in a solid form, then occupies void spaces both between
the strands of the braided sheath as well as between the strands of
the braided sheath and the outside surface of the strength member,
thus sealing off the braided sheath so that impurities and water
cannot pass through the braided sheath to the strength member.
Furthermore, the flowable adhesive substance both occupies void
spaces between the braided sheath and the outside surface of the
strength member, while also adhering the braided sheath to the
strength member.
[0091] When using the die downstream of the application point of
the flowable adhesive substance onto the outside surface of the
strength member, the die is designed, constructed, configured and
positioned so as to distribute more or less uniformly about the
outside surface of the strength member the flowable adhesive
substance. The surfaces of the die are selected of a material that
shall not hind to the flowable settable adhesive substance. As
mentioned supra, the braid point is immediately downstream of such
die, for the reasons described supra.
[0092] The thickness of the layer of the set adhesive substance,
i.e. the solid phase of the adhesive substance, at its widest zone
between the inside surface of the braided sheath and the outside
surface of the strength member, is selected so as to be less than
5% of the overall radius of the finished rope, and preferably is
less than 4% of such radius, yet preferably less than 3% of such
radius, yet more preferably less than 2% of such radius, yet even
more preferably less than 1% of such radius, and yet again even
more preferably less than 2 mm in thickness, and even more
preferably less than 1 mm in thickness, and yet even more
preferably less than 0.5 mm in thickness, and even yet again more
preferably less than 0.25 mm in thickness, and again even more
preferably less than 0.15 mm in thickness.
[0093] If the option of selecting the braid point, braid tension,
thickness of the coating, viscosity of the settable adhesive
substance and lag time so as to cause some of the flowable adhesive
substance to be forced through the strands forming the braided
sheath to the outside surface of the braided sheath is selected,
than the coverbraided strength member can pass through a second die
that smoothes the settable adhesive substance about the outside
surface of the braided sheath. The surfaces of this second die also
are of a material selected so as to not adhere to the settable
adhesive substance, as are the ambient temperatures about the
region of the die selected to preclude premature setting of the
adhesive substance while contacting the die. If it is desired to
use heat to set the settable adhesive substance, this step may be
done in a linearly shaped oven of about one to fifteen meters in
length, or lesser if lesser is sufficient, that the coverbraided
strength member is passed through prior to being wound up on the
take up spool, but after passing through the second die if such
second die step is selected, with the take up spool located
downstream of as well as external of the oven. The second die
preferably is located immediately downstream of the braid
point.
[0094] It is useful for the method of the present disclosure that
the flowable adhesive substance is dried, i.e. solid, prior to
contacting machinery or portions of machinery other than the dies,
and especially prior to the combination of the strength member, the
adhesive substance and the braided sheath being bent, such as being
bent about a wheel, capstan, pulley, winch, block or the like.
Furthermore, it is useful that the adhesive substance is set,
including dried, prior to contacting objects other than the
strength member and strands of the braided sheath, especially
objects that pull upon the outside surface of the braided sheath.
However, if it is not possible to enact such teachings, it is
important that the set time permit cleaning of the machinery from
excess of the settable adhesive substance prior to its setting.
[0095] For the settable adhesive substance polyurethane is
preferred. Passing through the oven, or otherwise in a controlled
environment facilitating setting of the settable adhesive
substance, sufficient heat is applied in sufficient lack of
humidity so as to accelerate adherence of the polyurethane or other
settable adhesive substance to both the outside surface of the
strength member and also to the inside surface of the braided
sheath, and in some cases to the outside surface of the braided
sheath.
[0096] Substances that accelerate the setting into a solid of the
polyurethane material or other settable adhesive substance, as are
conventionally known in the art, are selected for use with and in
the polyurethane blending machine. That is, such substances are
blended with the polyurethane or other settable adhesive substance
just prior to the settable adhesive substance being applied to the
outside surface of the strength member.
[0097] Additionally, substances that reduce drag and/or increase
the elasticity of the settable adhesive substance may be used, as
well as substances that increase its abrasion tolerance, and
resistance to degradation by elements such as light, heat, cold and
salt water can be added to the flowable settable adhesive substance
prior to its being situated onto the outside surface of the
strength member. Furthermore, substances that affect its affinity
to water, such as silicon or Teflon, or in certain applications
substances that enhance its affinity to water, can be blended with
the flowable settable adhesive substance.
[0098] The elasticity and/or also an elastomeric substance content
of the final and set phase of the settable adhesive substance is
selected so that such set substance does not prematurely crack or
separate from the inside surface of the braided sheath or from the
outside surface of the strength member during use, including
bending about sheaves and blocks suitable for any particular
diameter of the rope. The elasticity for the final, set phase of
the settable adhesive substance is as taught supra at the
temperature range taught supra, and at temperatures exceeding
negative 15 (-15) degrees Centigrade preferably is of from 20% to
550%, or even greater.
[0099] It is considered important for maximal strength and
longevity of the rope of instant disclosure that the strength
member itself as well as the filaments and strands forming the
strength member be contacted with an adhesive chemical agent, such
as a chemical agent suitable for use with filaments formed of
UHMWPE and LCP. Preferably, prior to the step of providing the
strength member, a step of removing some and preferably all or
nearly all humidity from the strength member followed by a step of
adding the chemical adhesive agent to the strength member is
selected. Then, the strength member containing the chemical
adhesive agent is provided, and the settable adhesive substance
situated on the strength member's outside surface prior to the step
of braiding the braided sheath about the strength member. As taught
above, the outside surface of the strength member preferably
includes the chemical adhesive agent that also is including within
the body of the strength member, especially in, about, between and
among the filaments and strands forming the strength member.
[0100] As taught above and herein, preferably such chemical
adhesive agent has an elasticity during its set phase that is
lesser than the elasticity of the set phase of the settable
adhesive substance. Furthermore, preferably the set phase of the
chemical adhesive agent has a friction when wet with water that is
greater than is a friction when wet with water of the set phase of
the settable adhesive substance.
[0101] Preferably, the strength member's chemical adhesive agent
includes a material having a friction when wet with water and
especially salt water that is a friction sufficient to measurably
increase the splice strength of the strength member.
[0102] In one embodiment of the present disclosure that is a
presently preferred embodiment, the braid angle of the braided
sheath is greater than the braid angle of the strength member.
However, in some cases the braid angle of the braided sheath may be
lesser than, or same as the braid angle of the strength member.
[0103] Preferably, the settable adhesive substance differs from the
chemical adhesive agent, as taught above and herein. However, in
some applications they may be the same or similar, though such
applications are not preferred.
[0104] It is important to the strength and longevity of the
synthetic rope of the present disclosure that the proportion of the
cross sectional area of the synthetic rope of the instant
disclosure that is occupied by the strength member be at least 40%
of the total cross sectional area of the rope, and preferably at
least 50% of the total cross sectional area of the rope, and yet
more preferably at least 60%, at least 65%, at least 70%, at least
75%, at least 80%, at least 85%, at least 90% and/or at least 95%
of the total cross sectional area of tile rope. This insures that
when bending over powered blocks, capstans, traction winches,
sheaves and the like that a suitable surface area of the outside
surface of the rope presses upon the strength member so as to not
cause premature failure of the settable adhesive substance.
[0105] When the strength member of the rope of instant disclosure
includes a pre-heat stretched strength member, or includes a
pre-heat stretched strength member having a core shaped so as to
support the naturally occurring interior shape of the strength
member, or further includes within the strength member any amount
of conductors, whether copper, fibre optic or the like, water
and/or electrical shields, and other, it is important to the
strength and longevity of the synthetic rope of the present
disclosure that the proportion of the cross sectional area of the
synthetic rope of the instant disclosure that is occupied by the
combination of the strength member and anything enveloped by the
strength member be at least 30% of the total cross sectional area
of the rope and more preferably at least 40% of the total cross
sectional area of the rope, and preferably at least 50% of the
total cross sectional area of the rope, and yet more preferably at
least 60%, at least 65%, at least 70%, at least 75%, at least 80%,
at least 85%, at least 90% and/or at least 95% of the total cross
sectional area of the rope. This insures that when bending over
powered blocks, capstans, traction winches, sheaves and the like
that a suitable surface area of the outside surface of the rope
presses upon the strength member so as to not cause premature
failure of the settable adhesive substance,
[0106] In a most highly preferred embodiment of the present
disclosure, the thickness of the wall of the braided sheath is less
than 16 mm (sixteen millimeters), and better less than 14 mm
(fourteen millimeters), better yet less than 12 mm (twelve
millimeters), yet again better less than 10 mm (ten millimeters),
yet again even more better less than 8 mm (eight millimeter), and
preferably less than 7 mm (seven millimeter), and more preferably
less than 6 mm (six millimeter), and yet more preferably less than
5 mm (five millimeter), yet even more preferably less than 4 mm
(four millimeter), further preferably less than 3.5 mm (three point
five millimeter), yet most preferably not more than 3 mm (three
millimeter), with approximately from 2 mm (two millimeter) to 3 mm
(three millimeter) being preferred, with at least 0.5 mm (half a
millimeter) being useful, depending upon the application intended
for the synthetic rope of the instant disclosure.
Preferred Spliced Eye and Sling Fabrication Methods
[0107] A preferred method of manufacturing and using the disclosed
rope is to manufacture a section of the disclosed rope with an eye
spliced at each end of the section of disclosed rope. A section of
the disclosed rope having an eye spliced at each end also is known
as a "sling" of the disclosed rope or as a "spliced eye sling" of
the disclosed rope. The known art does not teach a suitably strong
method for forming spliced eyes in a tightly coverbraided ropes.
Following is a presently preferred method for forming a spliced eye
into each end of a section of the disclosed rope, i.e. for forming
a sling of the disclosed rope. A section of the disclosed rope with
a spliced eye formed into each end of such section, i.e. a sling of
the disclosed rope, is most suitable for use in any of the
applications and uses mentioned herein as well as any other
applications and uses.
Preferred Sling Production Method
Terminology:
[0108] "Strength Member Core" also Means "Strength Member"
[0109] Step One: a predetermined length of strength member core is
selected (the predetermined length of strength member core
hereinafter referred to as the "core rope"). The core rope
preferably is a hollow braided rope. When the core rope is intended
for applications including but not limited to seismic applications,
paravane seismic lines, yachting lines, rigging lines, anchoring
lines, deep water oil rig mooring lines, towing warps and trawler
towing warps and and any other uses for rope, cable or chain, and
also such as when the core rope is made from a UHMWPE, a maximal
amount of a suitable impregnation substance included within the
strength member has been found to be advantageous.
[0110] Step Two: an eye is spliced at one end of the length o the
core rope, and preferably an eye is spliced at both ends of the
length of the core rope, forming a core rope sling. The preferred
splice method is to insert the cut end of the core rope into the
hollow body of the hollow braided core rope by opening up the braid
of the core rope and passing the cut end and the part of the core
rope intended to form the inserted portion of core rope forming
part of the splice braid zone into the body of the core rope
intended to form the external portion of the core rope forming part
of the splice braid zone, and then either leaving the cut end of
the core rope enclosed within the hollow body of the core rope in
the intended splice braid zone or pulling the cut end of the core
rope out of the body of the core rope at a point that is at an end
of the splice braid zone that is farthest from the eye formed by
this process.
[0111] Step Three: several core rope slings are attached to one
another in order to form a linear element formed of a series of
such core rope slings. The various core rope slings are attached to
one another to form such linear element by connecting subsequent
(and/or intended to be subsequent) core rope slings eye to eye with
sections of twine, the twine forming such sections of twine
hereinafter also known as "connecting twine". An intermediate
length of connecting twine is left in between the interconnected
eyes of each subsequent core rope sling so that such intermediate
length of connecting twine is about from five centimeters to 200
centimeters in length, or even more, depending upon the ultimate
length of the splice braid zone to be coverbraided. This
intermediate length of connecting twine equals approximately double
the length of any core rope sling's splice braid zone, or is even
about double such length plus an additional five to twenty
centimeters.
[0112] Step Four; the interconnected core rope slings are wound
upon a reel and/or spool that shall be used with or in conjunction
with a feed out spool and/or a feed out wheel of a conventional
braiding machine designed and configured to form braided sheaths
about lengths of rope and/or other linear elements. Care is taken
to impart minimal and preferably no rotation to the core rope
slings so as to avoid imparting torque to the final finished
product. In all cases care is taken to ensure that the core rope
slings remain torque free, i.e. lacking a tendency to rotate about
their longitudinal axis when tension is applied to the core rope
sling and/or to the finished product.
[0113] Step Five: a length of twine is passed over the take up
wheel and affixed to the take up spool at one end, such length of
twine hereinafter also known as the "take up twine". At another
location on the length of take up twine that corresponds to a
location intended for the braid point the various strands forming
the braided sheath, also are attached to the take up twine.
[0114] Care is taken to ensure that sufficient length of the take
up twine remains upstream of the braid point to permit future
knotting and connecting as is described further below, and that
such upstream portion of the take up twine is retained outside of
the converging braid strands in order to preclude it becoming
covered by or enclosed within a hollow braided sheath that is
intended to be formed, such withdrawn portion of the take up twine
also to be known hereinafter as the "withdrawn portion of take up
twine".
[0115] Step Six: the operation of the braiding machine is started
causing a hollow braided sheath formed of the strands to be formed,
if one is to be formed, such as when forming a braided sheath with
the process of the present disclosure.
[0116] Step Seven: after a predetermined length of the hollow
braided sheath is formed, such predetermined length corresponding
to about twice the length of the splice braid zone of any eye of
any core rope sling being used as a strength member core, plus an
additional about ten to twenty centimeters to be used for future
steps, the braiding machines operations are paused.
[0117] Step Eight: an eye of a first core rope sling that also is
an eye forming the distal end of the linear element formed of
several interconnected core rope slings and at least a
corresponding splice braid zone of the same first core rope sling's
eye are inserted into the interior zone of the converging strands
forming the hollow braided sheath, and then the eye is withdrawn
from within the interior zone of the converging strands forming the
hollow braided sheath by passing it through the converging strands
forming the hollow braided sheath proximal where such strands enter
the braid point.
[0118] Step Nine: the withdrawn eye is extended and collapsed, i.e.
not opened, and is laid alongside the section of hollow braided
sheath formed as a result of the above steps so that the base of
the eye, i.e. that portion of the open eye most proximal the splice
braid zone, is near the braid point, and the furthest portion of
the eye from the base of the eye is further downstream from the
braid point.
[0119] Step Ten: The action of the braiding machine is started
briefly so as to make preferably one wrap, and up to two, three or
four wraps of the strands forming the braided sheath about the
splice braid zone adjacent the withdrawn eye, then the action of
the braiding machine is again paused.
[0120] Step Eleven: The withdrawn portion of take up twine is
passed through the withdrawn eye of the first core rope sling and
knotted back on itself so as to affix the withdrawn eye of the
first core rope sling to the withdrawn portion of take up twine,
thus attaching the withdrawn eye to the take up wheel thereby
allowing to impart traction to the withdrawn eye and thus to the
entire core rope sling and any other core rope slings connected to
it.
[0121] Step Twelve: the hollow braided sheath is severed just
upstream of the point where the withdrawn length of twine attaches
to the hollow braided sheath.
[0122] Step Thirteen: While the braiding action of the braiding
machine is retained as paused, the take up spool is energized so as
to advance downstream the hollow braided sheath and the braid
point, thus tightening the withdrawn portion of take up twine
connecting the hollow braided sheath and the withdrawn eye.
[0123] Step Fourteen: the upstream severed length of hollow braided
sheath is now bent back (i.e. "doubled back") and passed through
the withdrawn eye and then passed into the interior zone of the
converging strands forming the hollow braided sheath and then laid
alongside the splice braid zone corresponding to the withdrawn
eye.
[0124] Step Fifteen: the take up wheel is now, if necessary,
reversed from its take up direction to a pay out direction so as to
cause the braid tension to become reduced and also so as to cause
the braid angle to become more obtuse, until the braid angle is
nearer to eighty-nine degrees than it is to seventy degrees when
measured between the braid ring and a converging strand used in
forming the hollow braided sheath, with a braid angle of about
eighty to eighty-seven degrees being also useful, with the result
that the core rope sling's material is not visible to an unaided
eye after the braided sheath has been formed about the splice braid
zone of the core rope sling.
[0125] Step Sixteen: the action of the braiding machine is then
commenced again, including that the take up spool again commences
to rotate in a "take up" direction, causing the braided sheath to
form about the splice braid zone corresponding to the withdrawn
eye.
[0126] Step Seventeen: when the braid point is proximal the point
of the splice braid zone that is furthest from the withdrawn eye,
the action of the braiding machine is again paused.
[0127] Step Eighteen: the take up spool is advanced while the
action of the braiding machine remains paused, so as to increase
the braid tension and also so as to create a less obtuse (i.e. more
acute) braid angle, with the result that the core rope sling's
material is not visible after the braided sheath has been formed
about a portion of the core rope sling not having a splice braid
zone.
[0128] Step Nineteen: the action of the braiding machine is again
started and continued to operate so as to cause the braided sheath
to form about the length of core rope sling up to the point that a
portion of the next splice braid zone arrives at the braid
point.
[0129] Step Twenty: the action of the braiding machine is again
paused, and the take up spool is again reversed, again reducing the
braid tension and again causing the braid angle to become more
obtuse, again so as to achieve the result that no portion of the
material forming the core rope sling is visible to the unaided eye
after the braided sheath has been formed about the splice braid
zone of the core rope sling.
[0130] Step Twenty-One: a "removable void spacer" is provided. The
void spacer may have its terminal ends bent at ninety degrees or
otherwise not parallel to the axis of the main length of the void
spacer, with such terminal ends' long dimensions preferably both
aimed in a similar orientation. A preferable removable void spacer
is formed of a hollow steel tube such as a hollow steel pipe having
a steel eye welded at one end of the pipe and having a high quality
steel cable of suitable diameter doubled over and inserted into the
other end of the steel pipe and held in place by solidifying a
molten bead weld inside the end of the pipe. The result of such a
construction method for a removable void spacer is a removable void
spacer designed and configured so as to result in a hollow steel
pipe having a loop of high grade steel wire protruding at one end
and having a steel eye affixed to its other end, such as may be a
link of steel chain welded to such other end of the hollow steel
pipe. Such preferable removable void spacer shall be known as "the
preferred removable void spacer".).
[0131] Step Twenty-Two: a preferred void spacer is situated
alongside the splice braid zone that is most proximal the braid
point in such a fashion that the steel eye of the preferred void
spacer as well as some length of the steel pipe of the preferred
void spacer is lying alongside the braided sheath while the
majority of the preferred void spacer's steel pipe is lying
alongside the core rope sling's still uncovered splice braid zone
in such a fashion that the steel pipe ends and the steel wire loop
commences where the exposed splice braid zone meets its open
spliced eye. To effectively so position the preferred void spacer,
it is needed to first insert the preferred void spacer into the
interior zone of the converging braid strands, and then to withdraw
that portion of it that is to lie alongside the braided sheath by
passing the steel eye of the preferred void spacer through the
converging strands forming the braided sheath proximal where such
strands enter the braid point. Step Twenty-Three: the take up wheel
is now again reversed from its take up direction to rather a pay
out direction so as to cause the braid tension to become reduced
and also so as to cause the braid angle to become more obtuse,
until the braid angle is nearer to eighty-nine degrees than it is
to seventy degrees when measured between the braid ring and a
converging strand used in forming the hollow braided sheath, with a
braid angle of about eighty to eighty-seven degrees being also
useful, with the result that the core rope sling's material is not
visible to an unaided eye after the braided sheath has been formed
about the splice braid zone of the core rope sling.
[0132] Step Twenty-Four: the action of the braiding machine is then
commenced again, causing the braided sheath to form about the
splice braid zone.
[0133] Step Twenty-Five: the action of the braiding machine is
again commenced including that the take up spool again commences to
rotate in a "take up" direction until the braided sheath is formed
to about the location where the splice braid zone meets its open
eye.
[0134] Step Twenty-Six: The braiding machine's operations are again
paused.
[0135] Step Twenty-Seven: a connecting line connecting the two open
eyes most proximal the braiding point is severed, and that open eye
having its splice braid already covered by the braided sheath is
withdrawn from within the interior zone of the converging braid
strands in a similar manner as described supra for withdrawing an
open eye from within such interior zone of converging braid
strands, and the other eye is retained on a hook that is provided
underneath the braid point.
[0136] Step Twenty-Eight: The braiding machines action is again
started so as to cause more hollow braided sheath to be formed
downstream of the withdrawn eye, the length of hollow braided
sheath to be formed again corresponding to about two times the
length of the splice braid zones present on the core rope slings
plus an additional about twenty centimeters of length.
[0137] Step Twenty-Nine: when about half the intended overall
length of the hollow braided sheath being formed in the above step
is completely formed, the braiding machine is again paused and a
section of twine is attached at the braid point to the strands
forming the hollow braided sheath, said section of twine being
about twice the length of a splice braid zone to be coverbraided,
and said section of twine being retained outside of the converging
braid strands. This section of twine is hereinafter also known as
the "next eye connecting twine". Step Thirty: the braiding machine
is again started and operated until the intended length of the
hollow braided sheath is formed.
[0138] Step Thirty-One: The eye of the core rope sling that has
been retained on a hook underneath the braid point is now inserted
into the interior zone of the converging braid strands, and then
withdrawing from such interior zone of converging braid strands in
the fashion as described above for withdrawing eyes from such
interior zone of converging braid strands, while the splice braid
zone corresponding to this eye is retained within the interior zone
of the converging braid strands so that it can be coverbraided.
This eye is then attached to the next eye connecting twine.
[0139] Step Thirty-Two: The length of hollow braided sheath is
severed about in half.
[0140] Step Thirty-Three: While the braiding action of the braiding
machine is retained as paused, the take up spool is energized so as
to advance downstream the hollow braided sheath and the braid
point, thus tightening the eye connecting twine that connects the
hollow braided sheath and the withdrawn eye.
[0141] Step Thirty-Four: the downstream severed end of the braided
sheath is inserted into the open portion of the steel wire loop
forming the terminal end of that void spacer nearest the end of
that eye already having had its splice braid zone coverbraided and
also having the preferred void spacer situated proximal its splice
braid zone. The severed end may be frayed prior to being so
inserted. Then the severed end is bend back, that is doubled over
the steel wire loop, and held in place by hand by being squeezed
together with the other portion of the hollow braided sheath near
the steel wire loop. The severed ends may be wrapped tightly with
tape and then cut into a spiked, tapered shape to facilitate such
insertion and retention.
[0142] Step Thirty-Five: the preferred void spacer is pulled out
(i.e. is withdrawing) from between the sheath and the core rope, in
a direction that draws the severed end of the braided sheath into
within the braided sheath and causes it to occupy a position
between the braided sheath and the core rope's splice braid zone
that previously was occupied by the preferred void spacer. A
hydraulic or pneumatic ram is useful for so withdrawing the
preferred void spacer. Optionally, a lubricant may be added to
assist in drawing the severed hollow braided sheath into position.
Such lubricant also may be used to lubricate the preferred void
spacer prior to its use. Such lubricant is especially useful should
the braided sheath be formed of highly inelastic materials such as
UHMWPE and others. This step may be made either when the portion of
splice braid zone with the preferred void spacer is upstream of or
downstream of the take up wheel, so long as tension is maintained
on the coverbraided core rope sling so as to permit withdrawing the
preferred void spacer. The take up wheel may be cushioned or padded
to permit the preferred void spacer to pass over it under tension
without damaging either the product being formed of the
machinery.
[0143] To produce further and subsequent spliced eye slings of the
rope of the present disclosure, the actions, steps, methods and
processes described in Steps Fourteen and onward are now repeated
in the order and sequence as described hereinabove in order to
produce the next spliced eye sling of the rope of the present
disclosure. Then, the Steps Fourteen and onward may again be
repeated, each time they are repeated another sling of the rope of
the present disclosure being formed, until the linear element
formed from the interconnected core rope slings is consumed. Then,
Steps One and onward are repeated in order to form more slings of
the rope of the present disclosure as desired.
[0144] Preferably, prior to splicing the eyes into any section of
core rope so as to form a core rope sling, a very abrasion
resistant, very durable sheath is slid upon the core rope and
maintained in a region corresponding to any intended open eye to be
formed, thereby resulting in a sheathed eye. The best construction
for such a sheath is a hollow braided construction that has been
made rigid by use adhesives and by forming a hollow braid of very
tight wraps about a rod or rope that is then removed from such
hollow braid where such rope or rope has a diameter that is
sufficiently larger than the diameter of the core rope to be
sheathed so that it is not difficult to pass the body of the core
rope into the sheath. The rigidity imparted to any eye by such
sheath greatly facilitates handling of the eyes in the production
process of the present disclosure, and also greatly increases
longevity of the spliced eye.
[0145] It is important that the braid angle and the elasticity of
fibers forming both the braided sheath and forming the strength
member of either the rope of the present disclosure or of the
spliced eye slings of the rope of the present disclosure, or of any
other rope or of any other sling of the present disclosure, are
selected so that the braided sheath and the strength member core or
their equivalents both experience total failure at the same
elongation of the final produced rope or its counterparts. For
example, when less elastic fibers form the braided sheath, and more
elastic fibers form the strength member core rope, the strength
member core rope's strands are of a less obtuse braid angle than
are the strands forming the braided sheath.
Further Preferred Fabrication Methods
[0146] When the rope of the present disclosure is to be used with
high tension powered blocks, it is advantageous to have the
disclosed thermoplastic core within the rope of the present
disclosure. In such instances of having the thermoplastic core
within the rope of the present disclosure, that portion of the
thermoplastic core corresponding to those portions of the core rope
of the present disclosure to be used in forming the splice braid
zone and optionally as well any open eye preferably is removed
prior to the splice being formed. Then, the core rope sling having
the thermoplastic core is coverbraided so as to form a tightly
coverbraided spliced eye sling having a thermoplastic core. It is
to be noted that the thermoplastic core is itself contained within
a sheath the stops molten and especially semi liquid phases of the
thermoplastic core from exiting the rope during extreme pressure. A
preferred production process of the present disclosure for
producing ultra high strength light weight ultra compacted spliced
coverbraided rope slings of the present disclosure is as
follows:
[0147] First: a thermoplastic core is provided, with or without
lead inside the core for weight, and with or without inside the
core insulated conductors designed and configured to tolerate being
permanently stretched as needed to survive the production process
now being disclosed, Polyethylene is a good material for most
thermoplastic cores for this process.
[0148] Second: the thermoplastic core is enclosed within a sheath
that is able to stop molten phases of the thermoplastic core from
exiting the sheath or that is able to mainly stop molten phases of
the thermoplastic core from exiting the sheath. Such a sheath can
be formed of very densely and tightly braided polyester fibers or
other fibers having a higher softening point than the softening
point of the thermoplastic core. Third: a strength member is formed
about the combination of the thermoplastic core and the sheath
enclosing the thermoplastic core. Preferred materials for forming
the strength member are fibers formed of materials that are able to
be creeped. For example, fibers of UHMWPE, such as Dyneema.RTM..
Creeped as used in this disclosure means that the fibers are able
to be permanently elongated a certain percentage of their initial
length under a certain tension and at a certain temperature,
especially a temperature just lower than a phase change temperature
of the material forming the fibers, without compromising the fibers
integrity and long term usefulness, and preferably also without
compromising the fibers strength. A preferred construction for
forming the strength member is a braided construction and
especially a hollow braided construction.
[0149] Fourth: an eye is spliced into one or both ends of the
strength member, with a portion of the thermoplastic core
corresponding to any intended splice braid zone being removed from
the intended splice braid zone prior to completion of the splicing
process and the sheath enclosing the thermoplastic core being tied
off and knotted so as to become sealed, rather than left cut open,
thereby stopping flow of future molten phases of the thermoplastic
core from exiting the sheath. The result is an alternative core
rope sling.
[0150] Fifth: the alternative core rope sling is transformed into
an alternative coverbraided spliced eye sling using the process of
the present disclosure for forming spliced eye slings of the
present disclosure. A preferred material for forming strands
forming the coverbraid is a material such as Dyneema or other
UHMWPE. A settable adhesive substance, or a substance capable of
being phase changed into an adhesive substance, where such adhesive
substances have an elasticity as taught herein for a settable
adhesive substance, including an elasticity of at least 10% at
between zero degrees centigrade and negative fifteen degrees
centigrade, and more preferably an elasticity of at least 50% at
such temperatures, and more preferably an elasticity up to and even
exceeding 550% at such temperatures and at temperatures that exceed
sixty degrees centigrade preferably is situated about the outside
of the strength member core, i.e, about the outside of the
alternative core rope sling, just prior to the convergence of
strands forming the coverbraided sheath about the outside of the
alternative core rope sling. That is, just prior to the formation
of any sheath about the alternative core rope sling. However, care
is taken to not situate the settable adhesive substance or its
equivalent about those portions of the strength member and/or core
rope sling corresponding the any splice braid zone, and the method
of the present disclosure includes a step of preventing the
settable adhesive substance and/or the second synthetic portion
from being formed about portions of the strength member and/or core
rope sling that correspond to a splice braid zone.
[0151] Sixth: excess of such adhesive substances are removed from
the outside of the braided sheath.
[0152] Seventh: the alternative coverbraided spliced eye sling
formed in the above step and of the combination of the alternative
strength member and the sheath enclosed thermoplastic core are next
subject to a tension that preferably is lesser than 50% of the
break strength of the alternative strength member, and more
preferably is less than 30% of such break strength, and yet more
preferably is less than 20% of such break strength, and yet more
preferably is less than 15% of such break strength, and yet again
more preferably is less than 10% of such break strength, and even
yet again is more preferably less than 7% of such break strength,
even more preferably is less than 5% of such break strength, with
about 3% of such break strength being preferred and with lesser
than 3% being useful
[0153] Eighth: The combination of the tensioned alternative
strength member and the sheath enclosed thermoplastic core are next
subjected to a heat that is regulated and applied in such a fashion
so as to cause all or at least the majority of the fibers forming
the strength member core to approach near to, but to remain at
lower than, their phase change temperature, while simultaneously
causing the thermoplastic core to change to a molten phase. It is
worth noting that the disclosed steps of first applying the
disclosed tension to the alternative strength member, whether or
not it is already used in forming either or both the alternative
core rope sling or the alternative coverbraided spliced eye sling,
and then subsequently applying the disclosed heat to at least the
alternative strength member, again whether or not it is already
used in forming either or both the alternative core rope sling or
the alternative coverbraided spliced eye sling, is contrary to the
trend in the industry and against the state of the art, and has
been found to surprisingly result in a stronger rope of the present
disclosure.
[0154] Ninth: the tension and temperature are maintained until a
desired amount of elongation of the strength member core can be
detected, and preferably until it is detected.
[0155] Tenth: While the tension is maintained on the strength
member, whether or not it is already used in forming either or both
the alternative core rope sling or the alternative coverbraided
spliced eye sling, and thus by extension also on the sheath
enclosed thermoplastic core as well as on anything enclosed within
the alternative strength member, the combination of any or all of
the alternative coverbraided spliced eye sling; the alternative
strength member and the sheath enclosed thermoplastic core and
anything else contained within the strength member is cooled until
the thermoplastic core has reach a solid phase, resulting in a high
strength light weight synthetic rope sling useful for all the above
mentioned uses.
[0156] Preferably, prior to splicing the eyes into the alternative
core rope in order to form the alternative core rope sling, the
above mentioned very abrasion resistant, very durable sheath is
slid upon the alternative core rope and maintained in a region
corresponding to any intended open eye to be formed, thereby
resulting in a sheathed eye. As taught above, the rigidity imparted
to any eye by such sheath greatly facilitates handling of the eyes
in the production process of the present disclosure, and also
greatly increases longevity of the spliced eye.
INDUSTRIAL APPLICABILITY
[0157] A rope may be formed by use of the teachings of the present
disclosure where such rope's intended use does not necessitate that
the rope either require tolerating the compressive forces generated
on high tension winches and drums, nor necessitate that the rope
exhibit the preferred rope elasticity and/or elasticity to break
point values as taught herein. In such embodiments, a strength
member is formed and the subsequent steps are carried out the same
as taught above and herein.
[0158] Although the present disclosure has been described in terms
of the presently preferred embodiment, it is to be understood that
such disclosure is purely illustrative and is not to be interpreted
as limiting. Consequently, without departing from the spirit and
scope of the disclosure, various alterations, modifications and/or
alternative applications of the disclosure are, no doubt, able to
be understood by those ordinarily skilled in the art upon having
read the preceding disclosure. Accordingly, it is intended that the
following claims be interpreted as encompassing all alterations,
modifications or alternative applications as fall within the true
spirit and scope of the disclosure.
* * * * *