U.S. patent application number 14/713967 was filed with the patent office on 2015-11-26 for rope products, systems, methods and applications.
This patent application is currently assigned to SOUTHERN WEAVING COMPANY. The applicant listed for this patent is Southern Weaving Company. Invention is credited to David Andrew Broadway, Cecil Curtiss Burdette, III.
Application Number | 20150337490 14/713967 |
Document ID | / |
Family ID | 53785693 |
Filed Date | 2015-11-26 |
United States Patent
Application |
20150337490 |
Kind Code |
A1 |
Burdette, III; Cecil Curtiss ;
et al. |
November 26, 2015 |
ROPE PRODUCTS, SYSTEMS, METHODS AND APPLICATIONS
Abstract
Embodiments of the present invention include rope products,
systems, processes, and related applications as disclosed
herein.
Inventors: |
Burdette, III; Cecil Curtiss;
(Easley, SC) ; Broadway; David Andrew; (Anderson,
SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Southern Weaving Company |
Greenville |
SC |
US |
|
|
Assignee: |
SOUTHERN WEAVING COMPANY
Greenville
SC
|
Family ID: |
53785693 |
Appl. No.: |
14/713967 |
Filed: |
May 15, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61993703 |
May 15, 2014 |
|
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Current U.S.
Class: |
428/34.5 ;
28/142; 428/34.1; 428/35.6; 428/36.2 |
Current CPC
Class: |
D07B 1/145 20130101;
D07B 2201/2096 20130101; D07B 2201/20903 20150701; B66C 1/122
20130101; D07B 1/148 20130101; D03D 3/02 20130101; D07B 1/12
20130101; Y10T 428/13 20150115; D07B 1/02 20130101; Y10T 428/1366
20150115; D07B 1/18 20130101; D07B 7/165 20130101; D07B 2201/2086
20130101; D07B 2201/2092 20130101; Y10T 428/1348 20150115; D07B
2201/2088 20130101; Y10T 428/1314 20150115 |
International
Class: |
D07B 1/12 20060101
D07B001/12; D07B 1/02 20060101 D07B001/02; D03D 3/02 20060101
D03D003/02 |
Claims
1. A rope system comprising: a cover having at least one channel
and two terminal ends; and a bundle of fibers that form a
continuous loop, wherein the bundle of fibers is at least partially
disposed within the cover and wherein a portion of the bundle of
fibers extends beyond the two terminal ends of the cover and are
exposed as loops.
2. The rope system of claim 1 wherein the bundle of fiber comprise
a length of material formed in a loop and having two terminal ends
of the material joined together to form the continuous loop.
3. The rope system of claim 1 wherein the cover is a woven cover
comprising a plurality of warp threads and a plurality of weft
threads and wherein the warp thread and weft threads are interwoven
together.
4. The rope system of claim 1 wherein the cover is comprised of
meta-, para-aramid fibers, para-aramid fibers, meta-aramid fibers,
cotton, rayon, Teflon.RTM.-coated fibers, shaped fibers, glass
fibers, basalt fibers, carbon fibers, high modulus polyethylene
fibers, liquid crystal polymer fibers, hollow fibers, nylon,
polyesters, polypropylene, polyethylene, polyphenylene sulfide,
polyetheretherketone, polyolefins, high modulus polyethylene
(HMPE), amide polymers or copolymers, other aramids, other suitable
materials, and combinations thereof.
5. The rope system of claim 4 wherein one or more of the warp
threads and weft threads comprise polymers, paraffin waxes,
non-paraffin waxes, or combinations thereof.
6. The rope system of claim 1 wherein the bundle of fibers are
comprised of polyester, nylon, meta- para-aramid fibers,
para-aramid fibers, meta-aramid fibers, cotton, rayon,
Teflon.RTM.-coated fibers, shaped fibers, glass fibers, basalt
fibers, carbon fibers, high modulus polyethylene fibers, liquid
crystal polymer fibers, hollow fibers, polypropylene, polyethylene,
polyphenylene sulfide, polyetheretherketone, polyolefins, high
modulus polypropylene, amide polymers or copolymers, other
polyolefins, other aramids, and combinations thereof.
7. The rope system of claim 1 wherein the bundle of fibers
comprises one or more of the structures selected from the group
comprising twisted continuous filaments, untwisted continuous
filaments, parallel strands, filament bundles comprised of
mono-filament yarns, filament bundles comprised of films, twisted
rope, braided rope, woven rope, kernmantle rope, woven ropes with
twisted or braided components, braided or twisted ropes with woven
components, and combinations thereof.
8. The rope system of claim 6 wherein at least a portion of the
bundle of fibers is coated with polymers, paraffin waxes,
non-paraffin waxes, or combinations thereof.
9. The rope system of claim 1 wherein the cover comprises and inner
cover and an outer cover.
10. The rope system of claim 1 wherein the cover comprises a
divider.
11. The rope system of claim 10 wherein the bundle of fibers that
form a continuous loop are disposed around the divider.
12. The rope system of claim 10 wherein a bundle of fibers is
disposed on each side of the divider.
13. The rope system of claim 1 wherein the cover comprises a
plurality of dividers and a plurality of channels.
14. The rope system of claim 13 wherein the cover comprises three
or more channels and a bundle of fibers is at least partially
disposed in at least three channels of the cover.
15. The rope system of claim 10 wherein the cover encases at least
a portion of a plurality of bundles of fibers.
16. The rope system of claim 15 wherein at least more than one of
the bundle of fibers is at least partially disposed within the
cover and extends beyond the two terminal ends of the cover and are
exposed as loops.
17. The rope system of claim 1 further comprising a joining
component configured to connect the loops of the bundle of fibers
that are exposed.
18. The rope system of claim 17 wherein a plurality of rope systems
are interlaced to form a linked rope system.
19. The rope system of claim 17 wherein the terminal ends of the
cover are adjoined to entirely encase the bundle of fibers.
20. The rope system of claim 1 wherein the cover is at least
partially disposed within a second cover and wherein the cover and
the second cover are unattached.
21. The rope system of claim 1 wherein the cover is configured to
have one or more properties selected from the group consisting of
high tensile strength, high thermal resistance, high abrasion
resistance, low shrinkage at high temperatures, high fatigue
resistance, ultraviolet radiation resistance, high chemical and
heat stability, and low moisture regain.
22. The rope system of claim 1 wherein the cover is configured to
provide an alert as a total breaking weight of t is approached,
wherein the cover comprises indicator yarns displaced within the
cover, wherein the indicator yarns have maximum load weights that
are less than the total breaking weight of the entire rope.
23. A linked rope system comprising: a fiber material configured in
a loop with joined ends to form a first bundle of fiber in a
continuous loop, wherein the first bundle of fiber is at least
partially encased within a first cover; a second fiber material in
a loop with joined ends to form a second bundle of fiber in a
continuous loop, wherein the second bundle of fiber is at least
partially encased within a second cover; wherein the first bundle
of fiber and the second bundle of fiber are interlinked.
24. The linked rope system of claim 23 wherein the second fiber
material is selected from the group consisting of a fiber material
having the same composition as the first fiber material and a fiber
material having a distinct composition from the first fiber
material.
25. The linked rope system of claim 23 wherein the first bundle of
fiber is entirely encased within a first cove and the second bundle
of fiber is entirely encased within a second cover.
26. A method of making a linked rope system, the method comprising:
looping a first fiber material and joining two terminal ends of the
first fiber material to form a first bundle of fiber in a
continuous loop, at least partially enclosing the first bundle of
fiber is at least partially encased within a first cover; looping a
second fiber material and joining two terminal ends of the first
fiber material to form a second bundle of fiber in a continuous
loop, at least partially enclosing the second bundle of fiber is at
least partially encased within a second cover; interlinking the
first bundle of fiber that is at least partially encased within a
first cover and the second bundle of fiber that is at least
partially encased within a second cover.
27. The method of claim 26 wherein the first fiber material is
looped through the first cover wherein the first cover has two open
terminal ends, and joining the two terminal ends of the first cover
together after the two terminal ends of the first fiber material
are joined, and wherein the second fiber material is looped through
the second cover wherein the second cover has two open terminal
ends and wherein the second fiber material is also looped through
the interior of the loop formed by the first bundle of fiber that
is at least partially encased within a first cover, and joining the
two terminal ends of the second cover together after the two
terminal ends of the second fiber material are joined.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a non-provisional application of U.S.
Provisional Application No. 61/993,703, filed May 15, 2014, which
is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Rope products, such as winches and slings, may have numerous
applications, and previous types of rope products are known in the
art. The present invention relates generally to novel rope
products, systems, processes, and related applications.
SUMMARY OF THE INVENTION
[0003] In an embodiment, the invention includes novel rope
products, systems, processes, and related applications as disclosed
herein. Generally, in one embodiment, the invention includes a rope
system. The rope system includes a woven cover having at least one
channel and two terminal ends, and the woven cover also includes a
plurality of warp threads and a plurality of weft threads and
wherein the warp thread and weft threads are interwoven together.
The rope system also includes a bundle of fibers that form a
continuous loop, and the bundle of fibers is at least partially
disposed within the woven cover such that a portion of the bundle
of fibers extends beyond the two terminal ends of the woven cover
and are exposed as loops.
[0004] In another embodiment, the invention includes a linked rope
system. The linked rope system includes (1) a fiber material
configured in a loop with joined ends to form a first bundle of
fiber in a continuous loop, wherein the first bundle of fiber is at
least partially encased within a first cover and (2) a second fiber
material in a loop with joined ends to form a second bundle of
fiber in a continuous loop, wherein the second bundle of fiber is
at least partially encased within a second cover. In addition, the
first bundle of fiber and the second bundle of fiber are
interlinked.
[0005] In yet another embodiment, the present invention includes a
method of making a linked rope system. The method includes the
steps of looping a first fiber material and joining two terminal
ends of the first fiber material to form a first bundle of fiber in
a continuous loop, and at least partially enclosing the first
bundle of fiber is at least partially encased within a first cover.
The method also includes the steps of looping a second fiber
material and joining two terminal ends of the first fiber material
to form a second bundle of fiber in a continuous loop, and at least
partially enclosing the second bundle of fiber is at least
partially encased within a second cover. Furthermore, the method
includes interlinking the first bundle of fiber that is at least
partially encased within a first cover and the second bundle of
fiber that is at least partially encased within a second cover.
[0006] The present invention may be better understood by reference
to the description and figures that follow. It is to be understood
that the invention is not limited in its application to the
specific details as set forth in the following description and
figures. The invention is capable of other embodiments and of being
practiced or carried out in various ways
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A full and enabling disclosure of the present invention is
set forth in the specification, which refers to the appended
figures.
[0008] FIG. 1 depicts a rope system pursuant to one embodiment of
the present invention;
[0009] FIG. 1A shows a cross-sectional view of the embodiment of
FIG. 1 along the line A-A;
[0010] FIG. 2 depicts a rope system pursuant to one embodiment of
the present invention;
[0011] FIG. 2A shows a cross-sectional view of the embodiment of
FIG. 2 along the line A-A;
[0012] FIG. 3 depicts a rope system pursuant to one embodiment of
the present invention;
[0013] FIG. 3A shows an end view of the embodiment of FIG. 3;
[0014] FIG. 4 depicts a rope system pursuant to one embodiment of
the present invention with a partial cutaway view and with a dashed
line representing how a divider may be formed in some
embodiments;
[0015] FIG. 4A depicts a further embodiment of the embodiment in
FIG. 4 wherein an embodiment of a divider is formed; a rope system
pursuant to one embodiment of the present invention;
[0016] FIG. 5 depicts a cover pursuant to one embodiment of the
present invention;
[0017] FIGS. 5B, and 5C depicts rope systems pursuant to various
embodiments of the present invention using the cover embodiment of
FIG. 5;
[0018] FIGS. 6 and 7 depict covers pursuant to certain embodiments
of the present invention;
[0019] FIGS. 7A, and 7B depict rope systems pursuant to embodiments
of the present invention;
[0020] FIG. 8 depicts a rope system pursuant to one embodiment of
the present invention;
[0021] FIG. 8A depicts an end view of the embodiment of FIG. 8;
[0022] FIG. 9 depicts a rope system pursuant to one embodiment of
the present invention;
[0023] FIG. 9A depicts an end view of the embodiment of FIG. 9;
[0024] FIG. 10 depicts a rope system pursuant to one embodiment of
the present invention;
[0025] FIG. 10A depicts an end view of the embodiment of FIG.
10
[0026] FIGS. 11 depicts an end view of the rope system embodiment
of FIG. 7B in a folded configuration;
[0027] FIG. 12 depicts an end view of the rope system embodiment of
FIG. 7A in a folded configuration;
[0028] FIG. 13 depicts a rope system pursuant to one embodiment of
the present invention;
[0029] FIG. 13A depicts an end view of the rope system embodiment
of FIG. 13 in a folded configuration;
[0030] FIGS. 14, 14A, 14B, and 14C depict embodiments of a weldable
or seamed cover pursuant to embodiments of the present
invention;
[0031] FIGS. 15A, 15B, and 15C depict embodiments of covers of the
present invention having auditory and/or visual indicators of
breakage;
[0032] FIG. 16 depicts a rope system pursuant to one embodiment of
the present invention;
[0033] FIG. 17 depicts the rope system of FIG. 16 in an additional
configuration;
[0034] FIG. 18 depicts a rope system pursuant to one embodiment of
the present invention; and
[0035] FIG. 19 depicts a cover having ribs pursuant to one
embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0036] Reference now will be made in detail to the embodiments of
the invention, one or more examples of which are set forth below.
Each example is provided by way of explanation of the invention,
not a limitation of the invention. In fact, it will be apparent to
those skilled in the art that various modifications and variations
can be made in the present invention without departing from the
scope or spirit of the invention. For instance, features
illustrated or described as part of one embodiment, can be used on
another embodiment to yield a still further embodiment.
[0037] Thus, it is intended that the present invention covers such
modifications and variations as come within the scope of the
appended claims and their equivalents. In addition, the use of
reference characters with the same two ending digits as other
reference characters in the present specification and drawings,
without a specific discussion of such structure, is intended to
represent the same or analogous structure in different embodiments.
Other objects, features and aspects of the present invention are
disclosed in or are obvious from the following detailed
description. It is to be understood by one of ordinary skill in the
art that the present discussion is a description of exemplary
embodiments only, and is not intended as limiting the broader
aspects of the present invention.
[0038] The present invention includes rope systems. In some
embodiments, such rope systems may include a bundle of fibers
displaced, partially or fully, within a cover. By way of example
and with reference to an illustrative embodiment, FIG. 1 shows rope
system 100. Rope system 100 includes a cover 102, which is shown as
a woven tubular cover having two open longitudinal ends, and fiber
bundle 104. As shown, fiber bundle 104 is comprised of fibers that
are continuously wrapped in a loop and then each end of the fibers
are joined by a knot (not shown). In this regard, the fibers are a
single length and the knot serves as the only connection point.
FIG. 1A shows a cross-section of the embodiment of FIG. 1 along the
line A-A. As shown, fiber bundle 104 extends beyond each
longitudinal end of cover 102 to form loops 105. In this depicted
embodiment, fiber bundle 104 may be formed and then inserted into
cover 102. In other embodiments, cover 102 may be woven around
fiber bundle 104 or, prior to being formed in a tubular shape,
cover 102 may be wrapped around fiber bundle 104 and then sealed to
form a tubular shape around cover 102. In other embodiments, fiber
bundle 104 may be formed by looping fiber bundle 104 within an
already-formed cover 102. In still other embodiments, cover 102 may
have an alternative shape, such as a flat shape or a square
shape.
[0039] In another exemplary embodiment, as shown in FIG. 2 (with a
partial cutaway view), rope system 200 includes cover 202, wherein
cover 202 is a tube-in-a-tube design having an outer cover 202' and
an inner cover 202''. FIG. 2A shows a cross-section of the
embodiment of FIG. 2 along the lines A-A. As shown, fiber bundle
204 form loops 204' and 204''.
[0040] In still another embodiment, as shown in FIG. 3, rope system
300 includes divider 306 disposed within inner cover 302'', such
that two channels are formed within inner cover 302''. As shown,
divider is centrally located within inner cover 302, but in other
embodiments it may be placed at alternative locations within inner
cover 302''. Fiber bundle 304 is disposed around divider 306. FIG.
3A shows a cross-section of the embodiment of FIG. 3 along the
lines A-A. In this embodiment, fiber bundle may be formed by
looping fibers inside inner cover 302'' and around divider 306, and
then tying the ends of the fibers with a knot. As shown in FIGS. 3
and 3A, divider 306 is a separate piece of material joined into 302
to form divider 306. In alternative embodiments, a divider may be
formed by joining portions of the inside cover 402'' together, such
as by weaving, sewing, or otherwise. For example, as shown in FIGS.
4 and 4A, cover 400 may have portions of its inner cover 402''
joined together (such as joining the points indicated by the dashed
line in FIG. 4A) to form a divider.
[0041] By further way of example, in still other embodiments, a
divider may be formed by joining separate covers together, such as
by weaving or sewing, such that the two joined covers join to form
a single cover having two channels separated by a divider, such as
shown in FIG. 5, which is an end view of such an illustrative
embodiment. In such embodiments, a fiber bundle may be looped
continuously through each channel (such as shown schematically in
FIG. 5B) or each channel may contain its own continuously-looped
fiber bundle (such as shown schematically in FIG. 5C). In similar
fashion, any suitable form of divider discussed herein may also be
present in the embodiment shown in FIG. 1 or in other
embodiments.
[0042] In some embodiments, multiple dividers may be present. By
way of example, as shown in FIG. 6, which is an end view of an
illustrative cover that may be used in connections with rope system
embodiments of the present invention, two dividers may be present
such that three channels are formed. As noted above with regard to
FIGS. 5B and 5C, a fiber bundle may continuously loop in one
channel or may continuously extend through two channels or all
three channels in the embodiment shown in FIG. 6. Although cover
600 is shown as a single-layer cover, alternative covers may be
employed using multiple dividers, including tube-in-tube cover
configurations. Similarly, the dividers in the embodiment of FIG. 6
are exemplary and any type of divider may be employed. In other
embodiments, more three or more dividers may be included. As shown
in FIG. 7, which is an end view of an exemplary cover, three
dividers may be employed, which forms four channels. In some such
embodiments, as with any embodiments described herein, each divided
section may contain a fiber bundle as shown in FIG. 7A or,
alternatively, a fiber bundle may be looped around a divider as
shown in FIG. 7B (wherein the B suffix added to the reference
numerals is merely to differentiate FIG. 7A).
[0043] In some embodiments, such as shown in FIGS. 8 and 8A, fiber
bundle 804 may be surrounded by a separate cover 803 that is
displaced within, but not adjoined to, cover 802. In still other
embodiments, multiple separate covers may be used as shown in FIG.
9. In such embodiments, a fiber bundle may be contained within a
single separate cover as shown in FIGS. 9 and 9A or may be looped
between two or more separate covers as shown in FIGS. 10 and 10A.
In still other embodiments, separate covers 803 and 903 may
optionally have a divider therein, wherein a fiber bundle may be
continuously looped in a single channel therein or between one or
more channels therein. In some embodiments, the separate cover,
such as separate cover 803, may be waterproof or water resistant,
and another cover, such as cover 802, may be abrasion
resistant.
[0044] In some embodiments, a rope system may be folded into a more
compact form. By way of example, FIG. 11 shows rope system 700B of
FIG. 7B, which illustrated a cover 702B having three dividers 706B
such that there were four channels. As shown in FIG. 11, folding
rope system 700B over in the latitudinal direction results in the
embodiment shown in the end view of FIG. 11. In similar fashion,
the embodiment of FIG. 7A may be folded to form the folded
embodiment shown in the end view depiction of FIG. 12. Finally, in
another exemplary embodiment, a rope system may have the
configuration shown in FIG. 13 and may be folded as shown in the
end view of FIG. 13A. In other embodiments, additional dividers and
channels may be present, and folding may be accomplished to form an
accordion-like folded rope system.
[0045] In some embodiments, a cover may extend along the entire
length or substantially the entire length of a winch or rope
system. In other embodiments, a cover may extend to or slightly
beyond any hardware at an end of the rope system. As shown in the
foregoing illustrative embodiments, a cover may extend over an
entire fiber bundle except for the loops of the fiber bundle that
extend from each longitudinal end of a cover. In some embodiments,
the cover may alternatively extend substantially over the entire
fiber bundle except the loops. In other embodiments, a cover may
also extend over the loops. In still other embodiments, a cover may
surround the loops and have an open portion on the interior of the
loop, in which case hardware may still be readily attached within
the open portion.
[0046] In the embodiments discussed above, each fiber bundle is
formed by continuously wrapping one or more continuous fibers and
then joining the free ends. In some embodiments, such free ends of
the fiber bundle may be joined by a knot. In other embodiments of
the illustrative embodiments herein, such free ends of a fiber
bundle may be taped, glued, or joined using any other suitable
methods. In some embodiments, the free ends of a fiber bundle ends
are not sewn, spliced, clipped, or clamped. Furthermore, a space or
gap may exist between the inside of a cover and the fiber bundle,
such as shown, by example, in FIG. 1A.
[0047] Covers used in the present invention may be comprised of any
suitable material for a particular embodiment. For example, in some
embodiments, the fibers of a woven cover may comprise any suitable
natural or synthetic material known in the art or combinations
thereof. In some embodiments, the fibers comprise meta-,
para-aramid fibers, para-aramid fibers, meta-aramid fibers, cotton,
rayon, Teflon.RTM.-coated fibers, shaped fibers, glass fibers,
basalt fibers, carbon fibers, high modulus polyethylene fibers,
liquid crystal polymer fibers, hollow fibers, nylon, polyesters,
polypropylene, polyethylene, polyphenylene sulfide,
polyetheretherketone, polyolefins, high modulus polyethylene
(HMPE), amide polymers or copolymers, other aramids, metal yarns,
other suitable materials, and combinations thereof. According to
some embodiments, such fibers may be heat-shrinkable or have
elasticity. By way of example, and without limitation, in some
embodiments a cover may include nylon and polyester fibers. In some
embodiments, any materials noted herein for a cover may be used for
a fiber bundle and any materials noted for a fiber bundle may be
used for a cover and vice versa. In addition, any materials used
for a cover or a bundle of fibers may be treated or coated to
improve the properties of the material for a particular
application.
[0048] In some embodiments, materials included in a cover may have
one or more of high tensile strength, high thermal resistance, high
abrasion resistance, low shrinkage at high temperatures, high
fatigue resistance, ultraviolet radiation resistance, high chemical
and heat stability, and low moisture regain. In some embodiments,
spun or texturized fibers or yarns may be used to limit abrasion.
Also, the fibers may be coated with polymers, paraffin waxes,
non-paraffin waxes, and/or other substances to improve abrasion,
ultraviolet resistance, water and chemical resistance, improve
moisture wicking, provide improved heat transfer, fire resistance,
and other desirable properties for a particular embodiment.
[0049] In some embodiments, a cover used in embodiments of the
present invention may be a woven webbing. The term "woven", as used
herein, means interlacing individual fibers in a regular order. Any
method of weaving known in the art may be utilized in this
invention. Similarly, any weave pattern known in the art may be
utilized in the webbing including, but not limited to, a plain
weave, a twill weave, a satin weave, a tabby weave, a taffeta
weave, a matt weave, a basket weave, a rib weave,
computer-generated interlacings, and combinations thereof. The
fibers of a cover may have any configuration known in the art. For
example, the configuration of the fibers may be circular, ovular,
elliptical, or flat. Additional configurations of woven material
are included in U.S. patent application Ser. No. 14/078,211, which
is published as U.S. Published Patent Application No. 2014/178,615
and which is incorporated herein in its entirety by reference. In
some embodiments, covers may have a construction and/or composition
other than a woven construction, such as a film cover, coated
fabrics, or combinations of different constructions.
[0050] In addition, in some embodiments, covers of the present
invention may include one or more spaced longitudinal ribs, such as
shown, by way of example, in FIG. 19. Such ribs, which may have
increased longitudinal stiffness, may be spaced equidistantly from
one another or may be spaced intermittently. In some embodiments,
the ribs may comprise a woven rope. The ribs may be formed from any
suitable material, including materials disclosed to form a cover or
a bundle of fibers herein. In some embodiments, ribs may be woven
into a cover, whereas in other embodiments they may be attached by
any conventional manner. The projection height of the ribs can
vary, but may be, in an embodiment, greater than the thickness of
the cover. In some embodiments, the projection height may be 5% to
200% greater than the thickness of the cover, including each
intermittent value therein. In some embodiments, the projection
height may be at least 5% greater than the thickness of the cover.
In another embodiment, the projection height 56 for the ribs may be
at least 10% greater than the thickness of the cover. In another
embodiment, the projection height of the ribs may be at least 20%
greater than the thickness of the cover. In yet another embodiment,
the projection height may be up to 50% greater than the thickness
of the cover and, in still another embodiment, the projection
height may be 100% greater than the thickness of the cover.
Additional configurations of ribbed covers are disclosed in U.S.
patent application Ser. No. 14/204,758, which is published as U.S.
Published Patent Application No. 2014/311,611 and which is
incorporated herein in its entirety by reference.
[0051] By way of example, and without limitation, covers in some
embodiments of the present invention may include warp yarns and
weft yarns having any suitable denier for a particular application.
For example, in some embodiments, warp yarns in the range of about
840 denier to about 2,700 denier may be used. In some embodiments,
warp yarns having greater than 2700 denier may be employed, such as
in the range of about 2,700 denier to about 5,000 denier. In some
embodiments, warp yarns having less than 3,000 denier may be used.
In some embodiments fill (or weft) yarn having a denier in the
range of about 500 denier to about 1,000 denier may be used. With
the foregoing exemplary ranges each intermittent value is
specifically included.
[0052] For embodiments employing a woven cover, any suitable
weaving parameters may be employed. By way of example, a cover may
have a tight plain weave, such as in the range of about 4.75 picks
per inch to about 50 picks per inch, including each intermittent
value therein. In some embodiments, a woven cover may have a pick
count of at least about 17.5 picks per inch. In some embodiments, a
woven cover may have a plain weave of about 2.5 to about 7.5 picks
per inch, including each intermittent value therein. In other
embodiments, an outer sleeve may have a pick count of at least
about 12.5 picks per inch. In some embodiments, a cover may include
an inner cover and an outer cover as previously described, wherein
an inner and outer cover may have the same woven configuration or
differing woven configurations. For example, in some embodiments an
inner cover may have a plain weave configuration and an outer cover
may have either a twill weave or a plain weave configuration. For
reference, a plain weave may also be referred to as a basket
weave.
[0053] In still other embodiments, covers may include non-woven
material that is sewn or otherwise connected in a tubular shape.
For example, in some embodiments, covers may be sewn, bonded, or
otherwise prepared using the same materials as discussed for woven
constructions or alternative materials. By way of example, in some
embodiments, a cover may be formed using weldable materials, By way
of example, a cover of some embodiments may be formed by coating a
webbing material, film, fabric, or other material (which may be, by
way of example, woven, spun bond nonwoven, nonwoven laminates,
films, perforated films, or combinations thereof) with a weldable
plastic, such as, for example, polyvinyl chloride or polyurethane.
In such weldable embodiments, any suitable weldable materials may
be employed, such as films, fibers, or nonwovens coated or uncoated
so long as the material can be joined by heat, ultrasonic, radio
frequency, welding, or the like.
[0054] By way of example, a rope system with a weldable cover may
be formed as shown in the illustrative embodiment of FIG. 14. As
shown, material 1401, which has longitudinal edges 1401', may be
laid flat, as shown in FIG. 14, and then it may be folded by
joining longitudinal edges 1401' to form a tubular shape, such as
that shown in FIG. 14A. Longitudinal edges 1401' may be welded to
form a seam. Any suitable seam may be used, such as those shown in
FIGS. 14B and 14C, which illustrate exemplary alternative welded
seams 1408' and 1408'' from an end view of a tubular cover. In some
embodiments, a hook and loop fastener or similar means may be used
to join longitudinal edges of a cover. Such welded covers may be
used in the manner described herein for any embodiment as a cover
for one or more fiber bundles. In addition, such covers with fibers
bundle may be used, for example, as a winch rope or, after joining
the ends of the tubular cover by any suitable joinder, such as by
welding, sewing, heat, ultrasonic, radio frequency, or in any other
suitable manner.
[0055] In some embodiments, and as illustrated in FIGS. 15A, 15B,
and 15C, embodiments of the present invention may include auditory
and/or visual indicators of breakage prior to a complete break of
the rope system. By way of example, covers made of woven material
may be used in certain embodiments of the present invention as
described above. Such woven covers may include both warp yarns and
weft yarns. As provided in some embodiments of the present
invention, these materials may provide the warnings necessary for
use in embodiments of the present invention. For example, although
most ropes are given maximum load requirements, the warp yarns
and/or weft yarns may include maximum load weights that are less
than the total breaking weight of the entire cover or fiber bundle
of a rope system or that are less than the maximum load weight of
the entire rope system. For example, in some embodiments, some or
all warp yarns and/or weft yarns in a rope may have maximum load
weights that are between about 20 and about 80% of the total
breaking weight of the entire rope system. In other embodiments,
warp yarns and/or weft yarns may include maximum load weights of
between about 40 and 60% of the total breaking weight of the entire
rope system. In such instances, as the maximum weight is
approached, the warp yarns and/or weft yarns will start to break,
thereby providing a user with visual and auditory warnings of
approaching breakage.
[0056] As shown in FIG. 15A, an exemplary woven rope includes warp
yarns 1502 and weft yarns 1504. As shown, FIG. 15B, the rope is
subjected to strain, and some of the weft yarns 1504 begin to break
as shown by broken weft yarns 1504'. in this manner, broken weft
yarns 104' may provide an iodination that the total breaking weight
of the entire rope is being neared or that a certain threshold of
strain or stress has been met. As shown in FIG. 15C, the exemplary
rope has undergone additional stress and some of the warp yarns
1502 have broken as shown by broken warp yarns 1502'. These broken
warp yarns 1502' may provide an additional indication of a certain
threshold being met or neared for the entire rope.
[0057] In some embodiments, additional materials, such as a
distinct weft strand or a distinct warp strand of a different
material than the other weft and/or warp strands, may be
incorporated into a rope to provide an indication of a threshold
being met or neared. For example, in one embodiment, such distinct
weft strands or a distinct warp strands may be of a weaker material
than the remaining weft or warp strands of the rope, such that when
the weaker distinct weft strand and/or distinct warp strands are
broken an indication is provided. In still other embodiments, an
additional material, such as a yarn that does not otherwise serve
as a weft strand or warp strand, may be incorporated into a rope to
provide an indication of a threshold being met or neared.
[0058] In addition, to provide even greater indications of
breakage, some or all weft yarns and warp yarns may be of various
colors such that a user may determine when a particular breaking
point is reached or is being reached. For example, in some
embodiments, some weft yarns may be of a different color, for
example red, than the other materials, such as white, utilized in
the rope construction. As load conditions are being reached, those
red weft yarns, optionally selected to break before the entire rope
system reaches a maximum breaking weight, will start to break and
will thereby provide the user with a clear indication of possible
breakage.
[0059] With regard to fiber bundles employed in embodiments of the
present invention, such fiber bundles may include any suitable
fibers or any other material suitable for a particular embodiment.
By way of example, such fibers and materials may include, without
limitation, polyester, nylon, meta- para-aramid fibers, para-aramid
fibers, meta-aramid fibers, cotton, rayon, Teflon.RTM.-coated
fibers, shaped fibers, glass fibers, basalt fibers, carbon fibers,
high modulus polyethylene fibers, liquid crystal polymer fibers
(such as, by way of example, those available from Vectran Fiber,
Inc.), hollow fibers, polypropylene, polyethylene, polyphenylene
sulfide, polyetheretherketone, polyolefins, high modulus
polypropylene, amide polymers or copolymers, other polyolefins,
other aramids, metal yarns, other suitable materials, and
combinations thereof. In addition, by way of example, the fiber
bundle may have any suitable structure, such as, without
limitation, twisted or untwisted continuous filaments, parallel
strands, filament bundles comprised of mono-filament yarns,
filament bundles comprised of films, twisted rope, braided rope
(including, without limitation, solid braided rope and hollow
braided rope), liquid crystal polymer rope, woven rope, kernmantle
rope, woven ropes with components that may be twisted or braided,
braided or twisted ropes using components that are woven or of
another format, and combinations thereof. By way of example, and
without limitation, such fibers in some embodiments may include
twisted, cabled, braided, or woven yarns, or combinations thereof.
In some embodiments, spun or texturized fibers or yarns may be used
to limit abrasion. According to some embodiments, such fibers may
be heat-shrinkable or have elasticity. Also, the fibers may be
coated with or otherwise include, such as by using nano-coatings
through vapor deposition or other suitable means, with polymers,
paraffin waxes, non-paraffin waxes, and/or other substances to
improve abrasion, ultraviolet resistance, water and chemical
resistance, improve moisture wicking, provide improved heat
transfer, fire resistance, and other desirable properties for a
particular embodiment. In addition, such materials and/or
alternative materials may be used in other non-woven covers that
are also within the scope of the present invention.
[0060] Any size of fibers may be used as is suitable for a
particular embodiment. Furthermore, any fibers employed may be
monofilament, multifilament, or tapes. In addition, the size of the
bundles shown in the figures herein are exemplary and are not
limiting. The fiber within a bundle may also be more tightly packed
within a bundle than shown in the depicted embodiment, as well as
bound, joined, braided twisted, or otherwise connected if desired.
In other embodiments, smaller or larger bundles may be employed. In
addition, in some embodiments, multiple bundles may be employed
within a single cover and, in some embodiments, even within a
single channel within a cover.
[0061] Any suitable denier of fiber may be used. In one embodiment,
the fibers of the woven rope may be in the range of about 10,000
denier to about 100,000 denier, including each intermittent value
therein. In some embodiments, fibers may have a denier of or
greater than about 10,000 denier. In still other embodiments,
fibers of or less than about 100,000 denier may be employed.
[0062] Fiber bundles may be wrapped as many times as suitable for
any particular embodiment or application. A predetermined length of
fiber may be selected based on the ultimate number of wrappings
desired and the desired length of the rope system. In some
embodiments, an increased number of wrappings may reduce the impact
on the connection of the ends of the fiber bundle, such as any
impact (such as from tension) at a knot joining the free ends of a
fiber bundle. In addition, although ends of a fiber bundle are
joined as a knot in the embodiments described above, other suitable
connections may be used such as taping, gluing, air splicing, and
other suitable connections. In some embodiments, the knot or other
connection may be disposed within a cover of a rope system.
[0063] In some embodiments, a fiber bundle may include a fiber
optic cable, a sensor wire, and/or other materials, such as for
load or temperature sensing. Such materials may be included within
a fiber bundle as described above or may be included as a separate
fiber bundle.
[0064] In some particular embodiments, rope systems of the present
invention may be used as a winch rope. In such embodiments, such as
shown in FIG. 16, fiber bundle 1604 is surrounded by cover 1602
except for loops 1605 that extend from cover 1602. Thimble 1615 may
be included on one loop 1605 for use in winch applications or other
applications. The depicted thimble is exemplary for one embodiment,
but any suitable thimble or other hardware may be used, In some
embodiments, each loop of that embodiment may include a thimble or
other suitable hardware. A metal hook may optionally be attached to
one or both ends, either to the fiber bundle loop directly or to a
thimble thereon. In some embodiments, one loop at a longitudinal
end of the rope system may be attached directly to a winch drum.
Winch rope system embodiments may be prepared from any of the
embodiments discussed herein.
[0065] In other embodiments, rope systems of the present invention
may be used to form or function as a round sling. Round sling
embodiments may be prepared from any of the embodiments discussed
herein. Such slings may be used to harness or support heavy objects
in applications such as, for example, aircraft, rigging, engine,
shipbuilding, or other industrial or construction-related tools and
parts. In some embodiments, a bundle of fibers may be continuously
wound and then partially or wholly encased within a cover, such as
by forming or joining a cover around the bundle of fibers. By way
of example, and with reference to FIG. 17, loops 1705 of rope
system 1700 may be joined together such that the rope system forms
a round sling. Any suitable hardware may be used to join loops
together to form a round sling, such as metal shackle 1716 shown
for exemplary purposes in FIG. 17. In addition, cover 1702 may
surround all or a portion of fiber bundles 1704. In some
embodiments, cover 1702 may surround all of fiber bundles 1705
except for loops 1705. In still other embodiments, cover 1702 may
not cover loops 1705, but after joining loops 1705 together to form
a round sling, then cover 1702 may be extended to cover a portion
or all of the loops, including or excluding any hardware. In such
embodiments, a terminal end at each end of cover 1702 may be
connected or joined together to form a continuous cover. Such
connection may be done by any suitable means, including fasteners.
In some embodiments, such round slings may be joined and connected
to create a chain or linked rope system as described below.
[0066] In other embodiments, the present invention further includes
a chain or linked rope system. Such linked rope systems may include
a plurality of a bundle of fibers in a continuous loop, optionally
encased wholly or partially within a cover, interlinked with other
bundles of fiber formed in a continuous loop and also optionally
encased wholly or partially within a cover. By way of example, FIG.
18 shows a linked rope system 1800. As shown, a bundle fibers 1804
(shown in a partial cutaway view) is encased within a cover 1802,
and such a fiber bundle is present (although not shown) within each
depicted cover 1802, which has two ends joined by seam S to form a
continuous circular cover. The cover and encased bundle of fibers
are interlinked with one or more other covers and encased bundle of
fibers as depicted.
[0067] Linked rope systems of the present invention may be formed
using any suitable procedure for a particular application. For
example, as shown with reference to FIG. 18, the bundle of fibers
are formed into a continuous loop of fibers by looping a fiber
material through an open cover, such as a cover having to open ends
(as shown in FIG. 18 for one cover 1804), and then joining two free
ends of the fiber material to form a bundle of fibers in a
continuous loop. A seam, such as seam S in FIG. 18, may then be
formed to join the ends of a cover together to form a circular
cover that fully encases the bundle of fibers within that cover. In
other embodiments, a bundle of fibers comprising a continuous loop
of fibers may be formed and then a cover may be formed or wrapped
around that already-formed bundle of fibers, such as by wrapping
material to form a cover around the already-formed continuous loop
of a bundle of fibers and then sewing a seam to form the cover in a
manner similar to that shown in FIGS. 14-14C. In still other
embodiments, round sling embodiments of the type previously
described above with respect to FIG. 17, may be used, wherein loops
of a bundle of fibers may be joined, such as by using any suitable
hardware, including pins, shackles, thimbles, hooks, and the like
made from appropriate materials for a particular application, such
as stainless steel, steel, plastic, or composites, to form a link.
A plurality of such links may be joined to form a linked rope
system. In addition, in some embodiments, links may be connected to
other links using hardware or by tying or sewing, as opposed to
interlinking. As noted, in some such embodiments, a cover may be
extended to cover the entire underlying bundle of fibers after
connecting the loops of the bundle of fibers. Although the
foregoing embodiments are illustrative, in other embodiments a
linked rope system may include a plurality of bundles of fibers are
interlinked and wherein some or all of the bundle of fibers do not
include a cover.
[0068] Rope systems of the present invention may be used for any
other suitable purpose, such as other types of slings, harnesses,
and ropes. Although particular embodiments of the invention have
been described using specific terms, devices, and methods, such
description is for illustrative purposes only. The words used are
words of description rather than of limitation. It is to be
understood that changes and variations may be made by those of
ordinary skill in the art without departing from the spirit or the
scope of the present invention, which is set forth in the following
claims. In addition, it should be understood that aspects of the
various embodiments may be interchanged in whole or in part.
Therefore, the spirit and scope of the appended claims should not
be limited to the description of the preferred versions contained
therein.
* * * * *