U.S. patent number RE45,778 [Application Number 14/010,165] was granted by the patent office on 2015-10-27 for composite fishing line.
This patent grant is currently assigned to Pure Fishing, Inc.. The grantee listed for this patent is Pure Fishing, Inc.. Invention is credited to Roger Cook, Joe Meyer, Jim Thelen.
United States Patent |
RE45,778 |
Cook , et al. |
October 27, 2015 |
Composite fishing line
Abstract
Braided or twisted lines made from a) gel spun polyolefin yarns
and b) at least one other yarn or monofilament are stretched to
increase line tenacity. If desired, stretching conditions can also
be chosen to significantly reduce the denier of the line.
Inventors: |
Cook; Roger (Spirit Lake,
IA), Thelen; Jim (Estherville, IA), Meyer; Joe
(Milford, IA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Pure Fishing, Inc. |
Columbia |
SC |
US |
|
|
Assignee: |
Pure Fishing, Inc. (Columbia,
SC)
|
Family
ID: |
45932877 |
Appl.
No.: |
14/010,165 |
Filed: |
August 26, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
12906312 |
Oct 18, 2010 |
8181438 |
May 22, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D07B
1/025 (20130101); D02J 1/22 (20130101); D02G
3/02 (20130101); D07B 5/12 (20130101); B29C
55/04 (20130101); D02G 3/444 (20130101); A01K
91/00 (20130101); D07B 2201/1096 (20130101); Y10T
428/2929 (20150115); D07B 2201/2036 (20130101); D07B
2201/1016 (20130101); D10B 2321/0211 (20130101); D07B
2501/2038 (20130101); D07B 2205/2039 (20130101); D07B
2205/2071 (20130101); D10B 2321/042 (20130101); D07B
2201/104 (20130101); B29K 2023/0683 (20130101); D07B
2205/2014 (20130101); B29K 2027/18 (20130101); D07B
2205/2014 (20130101); D07B 2801/10 (20130101); D07B
2205/2071 (20130101); D07B 2801/10 (20130101); D07B
2205/2039 (20130101); D07B 2801/10 (20130101) |
Current International
Class: |
D02G
3/02 (20060101); D02G 3/44 (20060101); A01K
91/00 (20060101) |
Field of
Search: |
;57/238,244 ;87/8
;43/44.98 ;428/373,374 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1054465 |
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May 1979 |
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CA |
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0110047 |
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EP |
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0197279 |
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Nov 1986 |
|
EP |
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0458343 |
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Nov 1991 |
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EP |
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0595320 |
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May 1994 |
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EP |
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0785302 |
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Jul 1997 |
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EP |
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1306471 |
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May 2003 |
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EP |
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1034328 |
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Jun 1966 |
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GB |
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01-139833 |
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Jun 1989 |
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JP |
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08-140538 |
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Aug 1994 |
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JP |
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2004-308047 |
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Nov 2004 |
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JP |
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2007-135500 |
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Jun 2007 |
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JP |
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WO 99/11355 |
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Mar 1999 |
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WO |
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WO 03/064760 |
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Aug 2003 |
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WO |
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WO 2007/021611 |
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Feb 2007 |
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WO |
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Other References
Okularczyk, "Experimental Investigations of Guide Rings Made of
UHMWPE and PTFE Composite In Water Hydraulic Systems", Archives of
Civil and Mechanical Engineering, vol. IV, No. 1, pp. 167-176
(2004). cited by applicant .
Poveromo, "The New Fluorocarbon Fishing Lines", Saltwater
Sportsman, vol. 61, Iss. 8, p. 20 (Feb. 2008) also found at
http://www.georgepoveromo.com/content.php?pid=75. cited by
applicant .
Silverstein et al., "A Polytetrafluoroethylene Filled Ultra-High
Molecular Weight Polyethylene Composite: Mechanical and Wear
Property Relationships", Polym. Engr. Sci., v. 35, No. 22, pp.
1785-1794 (Nov. 1995). cited by applicant .
Unal et al., "Sliding Friction and Wear Behaviour of
Polytetrafluoroethylene and Its Composites Under Dry Conditions",
Materials and Design, No. 25, pp. 239-245 (2004). cited by
applicant.
|
Primary Examiner: Hurley; Shaun R
Attorney, Agent or Firm: Johnson Legal PLLC
Claims
What is claimed is:
1. A composite fishing line with a net negative buoyancy in water,
said fishing line comprising: (a) a first line component consisting
essentially of a first yarn of filaments made of ultrahigh
molecular weight, high tenacity, polyolefin filaments, and (b) a
second line component comprising a second yarn or a monofilament
selected from the group consisting of: (A) partially-oriented
filament yarns comprising partially oriented (i) poly(trimethylene
terephthalate) yarn, (ii) poly(trimethylene
terephthalate)/poly(alpha-hydroxy acid) biconstituent filaments,
(iii) polyethylene terephthalate, (iv) nylon, (v) polyamides and
copolymers of polyamides, or (vi) polyvinylidene fluoride; (B)
poly(tetrafluoroethylene); and (C) expanded
poly(tetrafluoroethylene), said second line component exhibiting a
specific gravity of greater than 1.0, wherein said composite
fishing line has been re-drawn by stretching said composite fishing
line under tension and heat at conditions sufficient to increase
tenacity of the resulting fishing line by at least 10% relative to
its tenacity before the stretching.
2. A composite fishing line according to claim 1 wherein said first
yarn is made with filaments of polyethylene that exhibit a tenacity
of at least 15 g/denier and a tensile modulus of at least 500
g/denier.
3. A composite fishing line according to claim 2 wherein said
second filamentous line component is made with said second yarn
that comprises filaments of expanded poly(tetrafluoroethylene) or
poly(tetrafluoroethylene).
4. A composite fishing line according to claim 1 comprising 2-5
first component yarns of said first line component and 2-5 second
component yarns of said second line component.
5. A composite fishing line according to claim 4 wherein said first
line component and said second component have been braided or
twisted together to form said composite fishing line.
6. A composite fishing line according to claim 5 wherein said
fishing line has been re-drawn by stretching the composite fishing
line under tension and heat at conditions sufficient to increase
tenacity of the resulting fishing line by at least about 15%
relative to its tenacity before the stretching.
7. A composite fishing line according to claim 6 wherein said
fishing line has been re-drawn by stretching the composite fishing
line at a temperature within the range of about 110.degree. C. to
about 160.degree. C. and at a total draw ratio within the range
from about 1% to about 1000%.
8. A composite fishing line according to claim 6 wherein said
fishing line has been re-drawn at a temperature within the range of
about 135.degree. C. to about 155.degree. C.
9. A process for increasing tenacity in a sinking, composite
fishing line comprising: (a) a first line component consisting
essentially of a first yarn of filaments made of ultrahigh
molecular weight, high tenacity, polyolefin and (b) a second line
component comprising a second yarn or a monofilament, said second
component exhibiting a specific gravity of greater than 1.0; said
process comprising a step of: stretching the composite fishing line
under tension and heat at conditions sufficient to increase
tenacity of the resulting fishing line by at least 10% relative to
its tenacity before the stretching.
10. A process according to claim 9 wherein the stretching step
comprises stretching said composite fishing line at a temperature
within the range of about 135.degree. C. to about 155.degree.
C.
11. A process according to claim 10 wherein the stretching step
comprises stretching said composite fishing line to a total draw
ratio within the range from about 1.01 to about 9.0.
12. A process according to claim 9 wherein said first yarn consists
essentially of filaments of polyethylene that exhibit a tenacity of
at least 15 g/denier and a tensile modulus of at least 500
g/denier.
13. A process according to claim 12 wherein said second line
component comprises a second yarn that comprises an oriented or
partially oriented polymer.
14. A process according to claim 13 wherein said second yarn
comprises filaments of expanded poly(tetrafluoroethylene).
15. A process according to claim 13 wherein the stretching step
comprises stretching said composite fishing line to a total draw
ratio within the range from about 1.05 to about 3.0.
16. A process according to claim 13 wherein the stretching step
comprises stretching said composite fishing line to a total draw
ratio within the range from about 1.1 to about 2.0.
17. A process according to claim 13 wherein the stretching step
comprises stretching said composite fishing line to a total draw
ratio within the range from about 1.25 to about 1.5.
18. A composite fishing line according to claim 1 wherein said
second line component comprises a partially-oriented polyethylene
terephthalate yarn.
.Iadd.19. A composite fishing line according to claim 2 wherein
said first line component and said second component have been
braided or twisted together to form said composite fishing line
that exhibits a sinking rate of less than 2.5 in/s..Iaddend.
.Iadd.20. A composite fishing line according to claim 19 wherein
said fishing line has been re-drawn by stretching the composite
fishing line under tension and heat at conditions sufficient to
increase tenacity of the resulting fishing line by at least about
15% relative to its tenacity before the stretching..Iaddend.
.Iadd.21. A composite fishing line according to claim 19 wherein
said fishing line has been re-drawn by stretching the composite
fishing line at a temperature within the range of about 110.degree.
C. to about 160.degree. C. and at a total draw ratio within the
range from about 1% to about 1000%..Iaddend.
.Iadd.22. A composite fishing line according to claim 21 wherein
said fishing line has been re-drawn at a temperature within the
range of about 140.degree. C. to about 160.degree. C..Iaddend.
.Iadd.23. A braided or twisted composite fishing line comprising
3-64 yarns of first and second line components that have been
subjected to heated reorientation by re-drawing the composite
fishing line under a suitable combination of tension, heat and time
to irreversibly lengthen said composite line while reducing its
diameter and increasing its tenacity of the resulting re-drawn
fishing line relative to its as-braided or as-twisted state,
wherein: (a) said first line component consists essentially of
first filament yarns of highly oriented, ultrahigh molecular
weight, high tenacity, polyethylene filaments, whereby said first
filament yarns exhibit a tenacity within the range of about 35-50
g/d, and (b) said second line component consists essentially of
second filament yarns of expanded poly(tetrafluoroethylene), said
second line component exhibiting a specific gravity of greater than
1.0..Iaddend.
.Iadd.24. A braided or twisted composite fishing line comprising
3-64 yarns of first and second line components, wherein: (a) said
first line component consists essentially of first filament yarns
of ultrahigh molecular weight, high tenacity, polyethylene
filaments, and (b) said second line component consists essentially
of second filament yarns of expanded poly(tetrafluoroethylene),
said second line component exhibiting a specific gravity of greater
than 1.0, wherein said composite fishing line is in the form of a
braided, composite, fishing line made by braiding 40-600 denier
yarns into a composite fishing line that is then stretched under
tension and heat at conditions sufficient to increase tenacity of
the resulting stretched, braided, composite fishing line by at
least 10% relative to its tenacity before the
stretching..Iaddend.
.Iadd.25. A composite fishing line according to claim 24 wherein
said fishing line has an even number of yarns of each of said first
line component and said second line component and which are of
substantially equal denier of each yarn..Iaddend.
.Iadd.26. A fishing line according to claim 24 comprising 3-64
filament yarns in total that have been braided together before
stretching..Iaddend.
.Iadd.27. A composite fishing line with a net negative buoyancy in
water, said fishing line comprising filaments that consist
essentially of: (a) a first line component consisting essentially
of first filament yarns of ultrahigh molecular weight, high
tenacity, polyethelene filaments, and (b) a second line component
consisting essentially of second filament yarns of expanded
poly(tetrafluoroethylene), said second line component exhibiting a
specific gravity of greater than 1.0, wherein said composite
fishing line has been re-drawn in a substantially irreversible
manner by stretching said composite fishing line under tension and
heat at conditions sufficient to increase tenacity of the resulting
fishing line by at least 10% relative to its tenacity before the
stretching..Iaddend.
.Iadd.28. A fishing line according to claim 27 wherein the
stretched, braided, composite fishing line exhibits a sinking rate
of less than 2.5 in/s..Iaddend.
.Iadd.29. A fishing line according to claim 27 comprising 3-16
filament yarns in total that have been braided together before
stretching..Iaddend.
.Iadd.30. A composite fishing line according to claim 28 comprising
2-5 yarns of said first line component and 2-5 yarns of said second
line component..Iaddend.
.Iadd.31. A fishing line according to claim 27 wherein said fishing
line is made with filament yarns that each exhibit a size within
the range of about 20 denier to about 600 denier if braided and
within the range of about 20-1200 denier if twisted..Iaddend.
.Iadd.32. A fishing line according to claim 31 that has been
stretched in a post-formation drawing process in which composite
fishing line is heated in at least one oven, and the heated
composite fishing line is passed from an oven over and around a
draw roller that turns at a slightly faster rate than the speed at
which the heated composite fishing line exits said
oven..Iaddend.
.Iadd.33. A fishing line according to claim 31 wherein adjacent
filaments of said ultrahigh molecular weight, high tenacity,
polyethylene filaments are fused..Iaddend.
.Iadd.34. A process according to claim 9 wherein said composite
line is a braid of 3-16 yarns of said first line component and said
second line component..Iaddend.
.Iadd.35. A process according to claim 34 wherein each of said
composite line exhibits a size within the range of about 200 denier
to about 1200 denier..Iaddend.
.Iadd.36. A process according to claim 9 wherein said composite
line is a twisted composite of yarns of (a) said first line
component and (b) said second line component, wherein said
composite fishing line exhibits a neutral net twist..Iaddend.
.Iadd.37. A process according to claim 36 wherein each of said
composite line exhibits a size within the range of about 20 denier
to about 1200 denier..Iaddend.
.Iadd.38. A process for increasing tenacity in a sinking, composite
fishing line with a braided construction of 3-16 yarns of (a)
ultrahigh molecular weight, high tenacity, polyethylene filaments
and (b) expanded polytetrafluoroethylene filaments, each yarn
exhibiting a size within the range of about 40 to about 600 denier,
said process comprising: stretching the braided, composite fishing
line under tension and heat at conditions in a substantially
continuous process that are sufficient to increase tenacity of the
resulting stretched, braided, composite fishing line by at least
10% relative to its tenacity before the stretching..Iaddend.
.Iadd.39. A process according to claim 38 wherein the stretched,
braided composite exhibits a sinking rate of less than about 2.5
in/s..Iaddend.
.Iadd.40. A process according to claim 39 wherein the stretched,
braided composite exhibits a sinking rate of less than about 2.0
in/s..Iaddend.
Description
FIELD OF THE INVENTION
The present invention relates to a fishing line made with two or
more yarns of differing polymeric compositions. Preferably, these
yarns are collected by braiding or twisting to form fishing lines
of adequate diameter and tenacity that may then be further
processed by drawing the line under tension in one or more stages
to an even higher tenacity. Preferably, at least one of the yarns
is made with filaments of high tenacity, ultrahigh molecular weight
polyolefin fibers.
BACKGROUND OF THE INVENTION
Fishing lines based on ultrahigh molecular weight, high tenacity,
polyolefin yarns represented a dramatic shift in the technology of
fishing lines. The filaments and their manufacturing process are
described in Kavesh et al. U.S. Pat. No. 4,413,110; Smith et al.
U.S. Pat. No. 4,344,908; Smith et al. 4,422,993; Kavesh et al. U.S.
Pat. No. 4,356,138; Maurer E. P. 55,001; Harpell et al. U.S. Pat.
No. 4,455,273; Kavesh et al, U.S. Pat. No. 4,897,902; Neal U.S.
Pat. No. 5,277,858; and Kirkland et al. WO 94/00627. In general,
the filaments are made by spinning from a gel solution containing
the polymer in a solvent. As the solvent is removed from the spun
filament, the filament is stretched to form a high strength, high
tenacity filament of high molecular weight. Filaments made from
linear polyethylene or polypropylene exhibit a molecular weight of
at least 400,000, a tenacity of at least 15 g/denier, a tensile
modulus of at least 500 g/denier, a melting point of at least
140.degree. C.
Once bundled into yarns, a plurality of yarns can be made into an
excellent fishing line. Processes for doing so are described in
Cook U.S. Pat. Nos. 5,749,214; 5,540,990 and 6,148,597. The process
described in these patents generally teach a re-stretching or
"re-drawing" process under suitable heat and tension to cause the
fishing line to lengthen with an increase in tenacity.
Another process is described in Cunningham et al. U.S. Pat. No.
5,573,850 which discloses a yarn having a polyethylene core that is
then sheathed in a heated polymeric coating. The result of this
process is described as providing monofilament-like characteristics
to a multifilament construction.
The disclosures of each of these patents are herein incorporated by
reference.
The high tenacity and low degree of stretch while submerged in
water has made such fishing lines an important tool for anglers of
all skill levels. Despite their technological prowess for many
aspects of fishing, however, lines made from ultrahigh molecular
weight, high tenacity polyolefin yarns have one shortcoming for
some anglers: the lines float. With a specific gravity of only
0.97, some fishing techniques require that the fishing line have a
negative buoyancy to get the lure at the right depth with the right
action at that depth.
The use of weights added to the terminal end of the line do not
satisfactorily address the issues associated with a floating line.
For example, floating lines tend to pull a trolled lure to the
water's surface thereby requiring additional weight to pull the
lure back down. This combination of factors postures the lure in an
upward orientation or with a more sharply sloping angle to the
trailing line than would be desired. Floating lines may also
disrupt or prevent a fishing technique that relies on a nonmoving
lure that might stimulate a stunned prey.
It would be desirable to have a fishing line with the high tenacity
and low stretch properties that are characteristic of fishing lines
made with ultrahigh molecular weight, high tenacity, polyolefin
yarns but with an overall specific gravity of greater than 1.0 so
that the fishing line has negative buoyancy apart from any added
weight, terminal connector or lure. This is not as easy as one
might think.
A fishing line should have a relatively smooth exterior surface
along its entire length. Such smoothness dramatically affects the
drag resistance characteristics of the fishing line so surface
bumps, ridges and protrusions above the line surface are defects
that should be avoided to make a desirable fishing line. Thus, any
composite of fishing line yarns must consider the yarn accumulation
process, e.g., braiding, twisting or nonwoven formation, as well as
the processing temperature, duration, draw rate (if any), number of
draw stations and the chemistries associated with any processing
aids, lubricants, coatings or the like that are used during the
manufacturing process. All of the materials used in any composite
must act in substantially the same way, despite any differences in
chemistry, to minimize or avoid surface protrusions immediately
following manufacture as well as up to months after manufacture
despite a wide variety of packaging, shipping and storage
conditions and extremes.
It would further be desirable to have a sinking, composite fishing
line that would have a minimum of surface defects despite extended
storage conditions and environmental extremes.
SUMMARY OF THE INVENTION
It is an objective of the invention to provide a sinking, composite
fishing line and a method for its manufacture that use: (a) at
least one first component yarn that consists essentially of
ultrahigh molecular weight, high tenacity polyolefin yarn that is
buoyancy neutral or positive and (b) at least one second component
comprising a second filamentous yarn or monofilament made from a
material that has negative buoyancy, i.e., exhibits a specific
gravity of greater than 1.0.
It is another objective of the invention to supply a method for
making a sinking, composite fishing line that exhibits the high
strength and low stretch of ultrahigh molecular weight, high
tenacity polyolefin but with a net negative buoyancy.
In accordance with this and other objectives of the invention that
will become apparent from the description herein, fishing lines
according to the invention comprise: a composite fishing line with
a net negative buoyancy in water wherein the fishing line
comprises: (a) a first filamentous line component comprising a
first yarn consisting essentially of filaments made of ultrahigh
molecular weight, high tenacity, polyolefin and (b) a second
filamentous line component comprising a second yarn or a
monofilament, said second component exhibiting a specific gravity
of greater than 1.0.
A manufacturing process according to the invention comprises:
stretching the composite fishing line under tension and heat at
conditions sufficient to increase tenacity of the resulting fishing
line by at least 10% relative to its tenacity before the
stretching.
The composite fishing line of the invention counteracts the
normally buoyant nature of the high tenacity, polyolefin component
to provide a fishing line of high tenacity that has a net negative
buoyancy in water. The manufacturing process of the invention
re-stretches or "re-draws" this composite fishing line under heat
and tension that force the components to re-orient their molecular
structures into a composite fishing line of a smaller diameter but
with a tenacity that is at least 10% higher than the undrawn
composite while still retaining the net negative buoyancy that
allows the composite fishing line to be used in places and for
fishing styles that require a sinking line.
DETAILED DESCRIPTION OF THE INVENTION
Fishing lines according to the invention comprise: a composite
fishing line with a net negative buoyancy in water wherein the
fishing line comprises: (a) a first line component comprising a
first yarn comprising filaments made of ultrahigh molecular weight,
high tenacity, polyolefin and (b) a second line component
comprising a second yarn or a monofilament, said second line
component exhibiting a specific gravity of greater than 1.0. The
first and second line components are combined by either braiding or
twisting using an odd or even number of plies of first and second
line components.
Fishing lines according to the invention are preferably made with a
total of 3-64 first and second line components, preferably a total
of 4-10 line components made with yarns and, optionally,
monofilaments. An even number of plies permits the manufacture of
twisted fishing lines that have a net negative twist effect so the
resulting line stays twisted in use.
The first and second line components can be used for the fishing
line of the present invention in virtually any ratio, i.e., within
the range of 1:63 to 63:1. A preferred range of first line
component to second line component is within the range from 1:9 to
9:1 and even more preferably within the range of 1:3 to 3:1. The
best combination of strength to diameter ratio, sink rate and
fishing performance seems to be found in composite lines in which
an even number of yarns of both first and second line components
are used in a substantially equal total denier of each, i.e.,
braids having two yarns of each component (i.e.,
"2.times.200+2.times.200") in which all four yarns are about 200
denier each or a braid having four 100 denier yarns of first
component and two yarns of second component having a denier of 200
(i.e., "4.times.100+2.times.200").
The first and second line components for the present invention
preferably exhibit a size within the range from about 20 denier to
about 5000 denier. Larger yarn and monofilament sizes can be used
with a corresponding adjustment to the applicable processing
conditions. Preferred fishing lines are made with first and second
line components that exhibit a size from about 40 denier to about
600 denier. Even more preferred are fishing lines that use first
and second line components that are made almost completely of yarns
of their respective compositions.
The first line component is at least one yarn that consists
essentially of filaments made from ultrahigh molecular weight, high
tenacity polyolefin. Such materials are formed by spinning from a
gel and are often referred to as "gel spun polyolefins." Such
materials are characterized by an intrinsic viscosity of about 5-45
dl/g when measured in decalin at 135.degree. C. See Kavesh et al.
U.S. Pat. No. 4,413,110; Cook U.S. Pat. Nos. 5,749,214; 5,540,990
and 6,148,597; Cunningham et al. U.S. Pat. No. 5,573,850 and Tam et
al., Published U.S. Patent Application Publication No.
2008/0048355.
The gel spun polyolefin yarns are preferably made of ultrahigh
molecular weight, high tenacity polyethylene, polypropylene,
poly(butene-1), poly(4-methyl-pentene-1), their copolymers, blends
and adducts. Such yarns are characterized by a molecular weight of
at least 400,000 and more preferably at least about 800,000, and
most preferably at least about one million; a tenacity of at least
15 g/denier; a tensile modulus of at least 500 g/denier; and a
melting point of at least 140.degree. C. See, Kavesh et al. U.S.
Pat. Nos. 4,413,110 and 4,551,296 the disclosures of which are
herein incorporated by reference.
Gel spun polyethylene yarns are available in partially oriented
forms and highly oriented forms. See Tam et al., Published U.S.
Patent Application Publication No. 2008/0048355. Such
partially-oriented yarns (POY) generally exhibit a tenacity within
the range of about 12-25 g/d, as measured by ASTM D2256-02 at 25.4
cm (10 in.) gauge length at a strain rate of 100%. In contrast, the
highly-oriented yarns (HOY) are disclosed as exhibiting tenacities
within the range of 38-70 g/d. The examples found in the Tam et al.
published application show HOY tenacities of 37.0 to 45.7 for the
exemplified re-drawing process.
The process of the present invention is well suited for use with
first line component yarns that comprise gel spun polyolefin yarns
having a tenacity within the range of about 35-50 g/d. Such yarns
would be characterized as "highly oriented" but have been found to
respond to the present process by further elongation and even
greater strength-per-unit, e.g., tenacity or pounds force per
square inch in cross sectional area at break.
The second line component comprises a second yarn or a
monofilament. Preferably, the second line component can be further
drawn or elongated to a new, nonreversible length under drawing
conditions suitable for the first line component. Preferably, this
second line component can also benefit from additional stretching
under the heat and tensions needed for re-drawing the high tenacity
yarns of the first line component. Suitable second line component
yarn or monofilament materials include "partially-oriented"
filament yarns ("POYs"). Such yarns are made with filaments that
were not fully oriented during their manufacture. See, U.S. Pat.
No. 6,287,688 (partially oriented poly(trimethylene terephthalate)
yarn); published U.S. patent application no. 2008/0048355
(ultrahigh molecular weight, multifilament poly(alpha-olefin)
yarns); and U.S. Pat. No. 7,666,501 (manufacture of
poly(trimethylene terephthalate)/poly(alpha-hydroxy acid)
biconstituent filaments). Yarns from such filaments will lengthen
under the effects of heated re-drawing in a substantially
irreversible manner and will not retract when tension is removed
that might otherwise form kinks or discontinuities in the surface
of the fishing line.
Suitable second line components include poly(tetrafluoroethylene)
(PTFE), expanded poly(tetrafluoroethylene) (ePTFE), and
partially-oriented yarns of polyethylene terephthalate ("POY PET"),
nylon ("POY nylon"), other polyamides and copolymers of polyamides
("POY PA"), and polyvinylidene fluoride ("POY PVDF"). The preferred
second line component is a yarn that contains filaments of
ePTFE.
It should be noted here that the use of tenacity as a term for
comparison of the present composite line with other fishing lines
made from other gel spun polyolefin yarns has the potential to
mislead. Specifically, tenacity for yarns is a unit that measure
the ultimate breaking strength of the yarn (in gram-force units)
divided by the linear density of the yarn. The present composite
uses the strength of the first line component as the primary
strength of the composite. The second line component has a higher
linear density primarily for imparting a sinking characteristic to
the composite. As the second line component will likely not have a
specific strength that is as high as the first line component, the
resulting composite will reflect a lower tenacity than a
corresponding fishing line made only of a first line component
material.
The fishing lines of the present invention are preferably formed as
braids or twists of suitable first and second line components.
These braided or twisted lines may be used without further
processing or, preferably, are subjected to heated reorientation by
re-drawing the fishing line under suitable combinations of tension,
heat and time to lengthen the fishing line while reducing its
diameter and increasing the tenacity of the resulting fishing line
relative to its original "as-braided" or "as-twisted" state. The
heated post-formation processing of the present invention also has
the advantage of tightening the braid in a manner that is not
possible with conventional post-processing of braided lines.
Braided lines according to the invention are made with conventional
braiding equipment and 3-16 discrete yarns braided about a central
axis. The braid tightness (measured in "picks per inch") is
adjusted to provide a limp line of good surface quality according
to the prevailing standards of the line manufacturer. The braids
used as feed to the present fusion process preferably exhibit a
size within the range from about 100 denier to about 3000 denier
and more preferably within a range from about 200-1200 denier.
Yarns of the first and second line components can be braided to
produce a uniform distribution of each in the resulting fishing
line. If desired, one line component yarn may be used as a central
core around which are braided multiple yarns of the other line
component or combinations of yarns of the first and second line
components.
Twisted lines of the invention can be made from either single,
twisted yarns or in 2-4 ply, torque-balanced structures.
Preferably, the line is twisted to produce a neutral net twist,
i.e., the twisted fibers will remain intertwined even when free of
tensile loading. In the conventional language of the art, single
yarns are twisted in a "z" direction, while 2-4 of these z-twisted
yarns can then be plied together in the "s" (opposite) direction.
The "z" pitch and "s" pitch are chosen to balance the torque of
each twist. Twists are measured in terms of "twists-per-inch" (tpi)
or "twists-per-meter" (tpm). Like the braids, twists used as feed
to the present post-formation process preferably exhibit a size
within the range from about 100 denier to about 3000 denier and
more preferably within a range from about 200-1200 denier.
According to the invention, composite fishing lines can be used in
their braided or twisted forms without further processing. These
unprocessed fishing lines will exhibit good strength, a sinking
character when used for fishing and limp handling
characteristics.
Unprocessed braided or twisted composite fishing lines can be
substantially improved in overall fishing performance if they are
re-drawn in post-formation processing. Such processing can include
the addition of coloring agents, coating agents for color fixation,
and further re-drawing under combinations of tension and externally
applied heat that will cause the composite fishing line to stretch
irreversibly and reduce its overall diameter in a uniform manner
that forms more of an even better fishing line. If desired, the
heat and tension can be increased to permit fusion between adjacent
filaments of the gel spun polyolefin yarn used as component 1 in
the composite. See, Cook U.S. Pat. No. 6,148,597 the disclosure of
which is herein incorporated by reference.
One or more dyes, pigments or other colorants can be applied before
the fishing line enters the first heated stage of the re-drawing
process. Preferred coloring agents include water-based pigment
suspensions that are applied to the braided line so as to penetrate
the fishing line yarn structure and become intimately entrapped
therein.
If desired, other coloring materials can be applied to the surface
of the line, yarn, or filament and may coat only the surface or,
preferably, penetrate the structure of the fishing line yarn and
become intimately entrapped therein. Such other coloring materials
include mineral oils (e.g., heat transfer grade mineral oils with
an average molecular weight of 250-700) paraffin oils, and
vegetable oils (e.g., coconut oil). A preferred coloring material
contains a solution that includes a paraffin wax and mineral oil.
This coating acts as throughout the yarn structure and retains the
pigment solids during the re-drawing process while also helping to
form a smoother external surface. The smooth external coating may
also enhance casting distance by reducing surface friction on the
final fishing line as it passes through the lines guides of a
fishing pole.
The composite fishing lines are heated by passage through an oven
while under tension. One or more ovens can be used. Preferably 2-4
ovens are used to heat the line immediately before passing to a
draw roller.
The tension induced by the draw roller permits the fishing line to
withstand exposure to temperatures that are near, or even above,
the actual melting range of the component yarn filaments. The use
of a temperature that is too high for the speed and tension
conditions can cause the polymeric structure of the yarn filaments
to melt and lose tenacity, often resulting in a break with fully
melted ends. The precise conditions are highly dependent on the
specific equipment used, the denier of the yarns making up the
composite fishing line, the speed of the yarn down the line, and
the tension applied to the heated yarn by the draw rollers.
Oven temperatures should generally be operated at temperatures
within a range from about 110.degree. C. to about 160.degree. C.,
depending on the line tension and speed of advancement through the
oven. If the manufacturer desires to avoid filament fusion at
typical commercial manufacturing speeds, temperatures of about
140.degree.-150.degree. C. are typically useful to soften the
polymeric chains and allow them to slip and reorient into a
composite fishing line having a higher tenacity than before the
reorientation or re-drawing process. If surface fusion of adjacent
filaments is desired at typical commercial operating speeds,
temperatures of greater than about 150.degree. C. and up to a
temperature that is less than the melting range of the component
yarn filaments can be used. Surface fusion of the yarn filaments is
most preferably at a temperature within the range of about
150.degree. to about 160.degree. C. at commercial operating
speeds.
The heated line is then passed over and around a draw roller that
turns at a slightly faster rate than the speed of the line exiting
the preceding oven. The proportion of the exit speed to the speed
of the entering line is the "draw ratio" for that roller. This
difference in speed induces tension in the line and causes the line
to stretch. The "total draw ratio" is the product of the draw
ratios of all stages.
Overall, the fishing line is stretched in one or more drawing
stages at rates sufficient to increase the tenacity of the line by
at least about 10% relative to the yarn tenacity before drawn by
the present process. Preferably, the stretching is performed under
conditions sufficient to realize a tenacity improvement of at least
15%, and more preferably a tenacity improvement within the range
from about 15-200% relative to the original, unstretched, yarn used
to make the composite fishing line of the present invention.
Tenacity is improved by stretching the braided or twisted line at a
total draw ratio sufficient to increase the tenacity of the line
relative to the original line before stretching according to the
invention. Such stretching is performed at a total draw within the
range from about 1-1000% (i.e., a total draw ratio of 1.01-11.0),
preferably within the range from about 5-200% (total draw ratio of
1.05-3.0), more preferably within the range from about 10-100%
(draw ratio of 1.1-2.0), and particularly within the range from
about 25-50% (draw ratio of 1.25-1.5). Those in this art will
appreciate, however, that the specific total draw ratio that is
employed for any specific combinations of yarns will vary depending
on the specific yarn materials, yarn deniers, tension, heat and
residence time.
All documents, books, manuals, papers, patents, published patent
applications, guides, abstracts and other reference materials cited
herein are incorporated by reference in their entirety. While the
foregoing specification teaches the principles of the present
invention, with examples provided for the purpose of illustration,
it will be appreciated by one skilled in the art from reading this
disclosure that various changes in form and detail can be made
without departing from the true scope of the invention.
EXAMPLES
In the following examples, braided fishing lines are made with a
first line component of yarns of UHMW, gel-spun polyethylene and
ePTFE. In each instance, the number of yarns of polyethylene
filament yarns and the yarn denier are listed followed by the
number and denier of the polyethylene yarns.
Examples 1-2
A braided fishing line was made with four yarns of UHMW, gel-spun
polyethylene (4.times.100 denier) and ePTFE (4.times.200 denier) to
determine whether ePTFE could be drawn under two sets of conditions
that would be sufficient to re-draw the UHMW polyethylene yarn
which had a tenacity of about 40 g/d before it was braided. Two
samples of the same composite braid were processed in three,
heated, drawing stages at two different total draw ratios with oven
temperature adjusted for the higher draw ratio.
In both stages, the oven temperatures were adjusted to avoid
surface softening or filament fusion of adjacent filaments in the
gel spun polyethylene line used for component 1. If fusion was
desired to form a quasi-monofilament type of character, noting the
typical resistance of ePTFE materials to form surface bonds, higher
temperatures could have been used.
Ten samples of the resulting fishing line were then measured for
diameter to determine whether either component was relaxing once
tension had been removed or otherwise not irreversibly extended as
a result of the drawing process. The following Table 1 shows the
conditions and results.
TABLE-US-00001 TABLE 1 Example 1 2 Construction 4 .times. 100 PE +
4 .times. 100 PE + 4 .times. 200 ePTFE 4 .times. 200 ePTFE Total
Draw Ratio 1.25 1.5 Draw Roller 1 draw ratio 1.083 1.167 Oven 1
temp (.degree. C.) 150 152 Oven 1 res. time (s) 32.0 30.7 Draw
Roller 2 draw ratio 1.077 1.143 Oven 2 temp (.degree. C.) 145 151
Oven 2 res. time (s) 29.6 26.6 Draw Roller 3 draw ratio 1.071 1.125
Oven 3 temp (.degree. C.) 145 151 Oven 3 res. time (s) 27.6 23.5
Avg. Diameter (in.) 0.0133 0.0119 Avg. Break Strength (lb-force)
33.0 28.2 Final Denier 1054.0 883.5 Final Tenacity (g/d) 14.2
14.5
The results in Table 1 show that braids made with gel spun
polyethylene and ePTFE can, in fact, be re-drawn in post-formation
processing. Previously, ePTFE was not thought to be amenable to
reorientation processing. The fairly narrow range of diameters
around the average show that the braid is not exhibiting
post-relaxation puckering or loosening of the braid.
Examples 3-4
Examples 3 and show the construction and post-braid processing of
various constructions of fishing lines using gel spun polyethylene
yarns having an as-received tenacity within the range of about 44
g/d for component 1. Yarns of ePTFE were used for component 2. Ten
specimens were tested from each fishing line to arrive at the
stated values.
TABLE-US-00002 TABLE 2 Example 3 4 Construction 2 .times. 400 PE +
3 .times. 200 PE + 2 .times. 400 ePTFE 3 .times. 200 ePTFE Total
Draw Ratio 1.25 1.25 Draw Roller 1 draw ratio 1.083 1.083 Oven 1
temp (.degree. C.) 146 146 Oven 1 res. time (s) 28.4 28.4 Draw
Roller 2 draw ratio 1.077 1.077 Oven 2 temp (.degree. C.) 143 143
Oven 2 res. time (s) 26.3 26.3 Draw Roller 3 draw ratio 1.071 1.071
Oven 3 temp (.degree. C.) 143 143 Oven 3 res. time (s) 24.5 24.5
Mean Avg. Diameter (in.) 0.0165 0.0141 Mean Break Strength
(lb-force) 61.1 50.5 Final Denier 1472.9 1033.8 Final Tenacity
(g/d) 18.8 22.2
Examples 5-6
The fishing lines of Examples 5 and 6 were prepared and tested to
show the effects of using yarns of dissimilar deniers within the
same braid. Table 3 shows the details.
TABLE-US-00003 TABLE 3 Example 5 6 Construction 2 .times. 150 PE +
2 .times. 100 PE + 1 .times. 200 ePTFE + 2 .times. 90 ePTFE 1
.times. 90 ePTFE Total Draw Ratio 1.25 1.25 Draw Roller 1 draw
ratio 1.083 1.083 Oven 1 temp (.degree. C.) 146 146 Oven 1 res.
time (s) 28.4 28.4 Draw Roller 2 draw ratio 1.077 1.077 Oven 2 temp
(.degree. C.) 143 143 Oven 2 res. time (s) 26.3 26.3 Draw Roller 3
draw ratio 1.071 1.071 Oven 3 temp (.degree. C.) 143 143 Oven 3
res. time (s) 24.5 24.5 Mean Avg. Diameter (in.) 0.0100 0.0083 Mean
Break Strength (lb-force) 24.8 18.1 Final Denier 503.3 339.6 Final
Tenacity (g/d) 22.3 24.2
The information in Table 3 shows that yarns of dissimilar deniers
can be braided together and re-drawn according to the present
invention to produce a fishing line of good strength and
tenacity.
Examples 7-18
Table 4 shows the results of various tests and measurements of
braided yarns in Examples 7-18 that contain, by total denier, about
50% gel spun polyethylene and about 50% ePTFE. The Processed Braid
was treated by the post-formation re-drawing process of the present
invention.
TABLE-US-00004 TABLE 4 Nominal Break Sink Strength Strength Rate
Ex. Line ("lb test") Diameter Denier (lb) psi (in/sec) 7 Unproc- 10
0.01001 399.3 18.1 230,003 1.57 8 essed 15 0.01211 597.3 22.1
191,749 2.10 9 Braid 20 0.01397 847.6 21.8 142,052 2.40 10 30
0.01723 1221.9 45.3 194,414 2.67 11 50 0.02033 1784.4 54.0 166,391
3.06 12 100 0.02902 3427.7 86.2 130,323 3.68 Avg. psi 175,822 13
Proc- 10 0.00830 339.6 18.1 334,538 1.69 14 essed 15 0.01000 503.3
24.8 315,773 2.20 15 Braid 20 0.01190 697.5 33.9 304,810 2.67 16 30
0.01410 1033.8 50.5 323,427 3.03 17 50 0.01650 1472.9 61.1 285,757
3.28 18 100 0.02300 2882.1 126.0 303,276 4.39 Avg. psi 311,263
Improvement due to processing 77%
Inspection of the data in Table 4 will show that an unprocessed
braid according to the invention exhibited sinking rates
proportional to the amount of ePTFE in the composite. Substantial
improvements are found when the braid is re-drawn under total draw
rate, heat and tension parameters of the preferred conditions for
the post-formation process described above. Notably, denier
decreased in all braid sizes while the break strength stayed the
same or improved. The average psi--pounds force per square inch of
cross sectional area--increased an average of 77% due to the
post-formation processing of the present invention.
Examples 19-44
Braids of UHMW polyethylene yarns (DYNEEMA SK-75 available from DSM
N.V., "PE") and ePTFE yarns were re-drawn according to the
invention and tested for sinking rate. The results of these samples
against a variety of comparative examples are shown in Table 5.
TABLE-US-00005 TABLE 5 Avg. Sink Average Rate No. of Den- Ex. Line
Type (In/s) Yarns Denier sity 19 8 .times. 200 SK75 + 200 PTFE core
0.00 8 2192.1 0.843 20 8 .times. 100 SK75 + 200 PTFE core 0.67 8
1198.5 0.998 21 PE/Dacron braid 10# 0.70 4 433.1 0.998 22 PE/Dacron
braid 20# 0.75 4 669.6 0.998 23 8 .times. 200 SK75 + 400 PTFE core
0.75 8 2384.4 0.871 24 2 .times. 400 SK75 + 2 .times. 400 PTFE
braid 1.12 4 1798.2 1.214 25 2 .times. 100 SK75 + 2 .times. 90
ePTFE braid 1.33 4 431.1 0.998 26 4 .times. 100 SK75 + 4 .times. 90
ePTFE braid 1.38 8 867.9 1.183 27 2 .times. 100 SK75 + 2 .times. 90
ePTFE braid 1.44 4 443.6 0.998 28 4 .times. 100 SK75 + 4 .times. 90
ePTFE braid 1.50 8 855.8 1.167 29 8 .times. 100 SK75 + 400 PTFE
core 1.53 8 1403.2 1.059 30 3 .times. 100 SK75 + 3 .times. 90 ePTFE
braid 1.59 6 633.9 1.171 31 3 .times. 100 SK75 + 3 .times. 90 ePTFE
braid 1.69 6 666.8 1.238 32 PE with PVDF core yarn 20# 1.78 4 plus
861.1 1.160 core 33 2 .times. 200 SK75 + 2 .times. 200 PTFE braid
1.91 4 953.7 1.106 34 PE with PVDF core yarn 40# 1.97 8 plus 1711.3
1.148 core 35 4 .times. 200 aramid + 200 PE core 2.07 4 plus 1051.5
w/yellow coating core 36 4 .times. 400 SK75 + 4 .times. 400 PTFE
braid 2.08 6 3721.3 1.052 37 4 .times. 200 aramid + 200 PE core w/
2.12 4 plus 1065.6 green coating core 38 4 .times. 200 aramid + 100
PE core w/ 2.14 4 plus 644.8 green coating core 39 2 .times. 200 +
2 .times. 400 PE + fibreglass 2.57 4 2839.1 1.224 core 40 4 .times.
100 PE + 4 .times. 200 PTFE braid 2.94 8 1451.0 41 200 SK75 core +
8 .times. 90 ePTFE 2.96 8 994.6 1.686 braid 42 400 SK75 core + 16
.times. 90 ePTFE 3.53 16 1954.1 1.220 braid 43 400 SK75 core + 16
.times. 90 ePTFE 3.67 16 1885.0 1.558 braid 44 PE and PTFE braid
over lead core 17.60 8 16938.0 5.448
The information in Table 5 shows that increasing levels of heavier,
second line component materials (e.g., ePTFE, PVDF, fibreglass, and
aramid yarn or monofilament) in the composite fishing line increase
the density of the fishing line and, correspondingly, the sink
rate. A fishing line that is too heavy and too dense is, however,
difficult to cast and is most suited for use as a line for
trolling, ice fishing, jigging and similar forms of fishing that do
not require dynamic casting. It was found that fishing lines
exhibiting a sink rate of less than about 2.5 in/s can be cast with
those having a sink rate of less than about 2.0 presented the
better balance of casting distance and sink rate.
* * * * *
References